Interelectrode gas-liquid-solid three-phase flow analysis and simulation for drilling holes with high aspect ratio by micro-EDM

In micro-electrical discharge machining (micro-EDM) using the non-hollow circular cross-section tool electrode with the side flushing technique, when the aspect ratio of machined micro-hole is expected to be further increased, the discharge debris expelling speed and the working fluid renewal efficiency are weakened, which hinders the improvement of machining efficiency and accuracy with increased machining depth. In order to reveal the flow behavior of the working fluid in the micro-EDM gap, so as to realize the high-precision and high-efficiency machining of micro-hole with high aspect ratio, a three-phase flow simulation model of fluid, bubble, and debris is established in Fluent under the ideal assumption that the spark discharges occur continuously to generate high-pressure bubbles. The simulation results show that when the boundary condition of the flushing pressure at the side gap entrance is set to 0, the pressure wave emitted when the high-pressure bubble expands, which is formed by the instantaneous gasification of the working fluid between electrodes under high temperature, is the source of pneumatic force that drives the working fluid flow at the micron scale. Affected by the gap flow channel structure and the viscous resistance from inner wall, the flow velocity direction of the fluid dragging the discharge debris to rise up and expel will change, forming a dynamic alternation process of flowing into and out of the side machining gap entry. As the machining depth increases, due to the energy attenuation of the pressure wave propagating from the bottom gap to the side gap entrance, the expelling speed of the discharge debris decreases exponentially at the side gap entrance, resulting in the reduced machining efficiency and accuracy. However, when the simulated bubble generation frequency is increased to the megahertz level, the expelling efficiency of debris has a step-like improvement. The continuous and high-frequency generation of high-pressure bubbles can maintain a high pressure gradient in the bottom gap, and the discharge debris is able to continuously move upward without falling back to accumulate in the bottom gap, which is beneficial to the stable and smooth machining process, realizing the high-precision and high-efficiency machining of micro-hole with high aspect ratio.