M. Sen∗ and H.S. Shan∗∗
Electrochemical drilling, electro jet drilling, finite element method, radial overcut Nomenclature A Area machined [mm2 ] D Diameter of electrolyte jet [mm] DR Drilling rate [mm min−1 ] DTM Difficult-to-machine E Electrochemical equivalent of the work material [kg Coulomb−1 ] Ev Effective applied voltage [V] F Faraday’s constant [Coulomb] GTW Gap between the capillary tip and the workpiece [mm] IEG Inter electrode gap [mm] I Current flowing through IEG [A] K Electrical conductivity
The electro jet drilling (EJD) process is gaining prominence in the machining of micro and macro holes in difficult-to-machine materials used in aerospace, electronics and computers, medical, and automobile industries. As the trend towards miniaturization continues, this process is gaining increasing importance as it has shown its superiority over other contemporary non-conventional micro and macro hole drilling processes. This paper presents a two-dimensional finite element model for the analysis of the EJD process using quadrilateral (rectangular) elements. The developed model predicts the drilling rate and radial overcut. Experimental results indicate close agreement with the simulated results.
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