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DIS_Sputter Erosion Model of Arcing Contact Materials.pdf

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THE ROLE OF INTERELECTRODE DISTANCE IN ELECTRICAL DISCHARGE MACHINING by HANS C. JUVKAM-WOLD S.B., Massachusetts Institute of Technology S.M., Massachusetts Institute of Technology (1966) (1967) Submitted in partial fulfillment of the requirements for the degree of Doctor of Science at the MASSACHUSETTS INSTITUTE OF TECHNOLOGY May, 1969 Signature Certified of Author..... . ... a...... .. Dept. of Mechanical Engineering, May 15, 1969 by.. . .. . , 4. . . .. . . .. .. ..
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  THE ROLE OF INTERELECTRODE DISTANCE IN ELECTRICAL DISCHARGE MACHINING by HANS C. JUVKAM-WOLD S.B., Massachusetts Institute of Technology S.M., Massachusetts Institute of Technology (1966) (1967) Submitted in partial fulfillment of the requirements for the degree of Doctor of Science at the MASSACHUSETTS INSTITUTE OF TECHNOLOGY May, 1969 SignatureCertified of Author..... .... ...... .. Dept. of Mechanical Engineering, May 15, 1969 by.. ... . , . .... .... .. .. .............. * 000 -00 00 Xesis Supervisor Accepted by.............0 ..4 .2..,......-9 96 O.... ................... Chairman, Departmental Committee on Graduate Students Archives INST. TEC 4 JUN 2 4 1969 LIBRARIE  by Hans C. Juvkam-Wold Submitted to the Department of Mechanical Engineering on May 15, 1969 in partial fulfillment of the requirementsfor the degree of Doctor of Science.ABSTRACTThe interelectrode distance between tool and workpiece in electrical discharge machining has been measured using a flow rate technique. The magnitude of the electrode separation is found to be approximately proportional to the one third power of the pulse energy. The quantity of material eroded from a steel workpiece per discharge in multiple discharge machining tests using a graphite tool is proportional to the pulse energy, irrespective of the workpiece polarity, for pulse durations from 20 to 500 microseconds and are currents from 40 to 300 amps. Erosion products appear partly in the form of hollow spheres, and measurements of the size distribution indicate that the mean size increases with increasing nulse energy. The magnitude of the interelectrode distance and the diameter of the largest spheres are both of the same order, suggesting that the distance may be controlled by the size of the spheres. An attempt was made to force the distance to be large by introducing spheres into the EDM fluid, but the results were unsatisfactory.In reverse polarity the relative erosion of the graphite anode is found to be greatly reduced at high pulse energies. A qualitativeerosion model which assumes (1) he nower density at the anode surface decreases as the interelectrode distance increases, and (2) aterialtransfer to the anode increases as the gap increases, is suggested andexamined in the light of the experimental data. Thesis Supervisor: Robert E. Stickney Title: Associate Professor of Mechanical Engineering -2- THE ROLE OF INTERELECTRODE DISTANCE IN ELECTRICAL DISCHARGE MACHINING  To Connie  ACKNOWLEDGEMENTS The author is ost grateful to Professor R. E. Stickney for serving as thesis supervisor, and for suggesting the problem. His interest guidance and continuous encouragement throughout the course of this work were invaluable. Special recognition is given to Mr. Viswanathan, the author'sco-worker, for stimulating discussions, thoughtful criticisms, and inspiring comments. The author wishes to thank the other members of the thesiscommittee, Professors Adams, Cook, Mikic, and Nayak, and Dr. Waymouth of Sylvania, for critical evaluation and comments, and for theirinterest and helpful suggestions. Appreciation is extended to Mrs. Rose Hurvitz and to all the other members of the Thermodynamics and Kinetics group for their part in contributing to an enjoyable work environment.The author further wishes to acknowledge the fellowshipsupport of the Mene Grande Oil Company (Gulf), the M.I.T. Research Laboratory of Electronics, and the Department of Mechanical Engineering. Thanks go also to the Elox Corporation of Michigan for providing the EDM equipment.
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