Finite Element Based Thermal Modelling for Optimized Parameter and Experimental Validation of Aluminium-Silicon Carbide During Electrical Discharge Machining Assisted Drilling Process

Brajesh Kumar Lodhi; Rohit Sahu; Vinod D. Golakiya; Tushar P Gundarneeya; Yogesh Dinkar Jadhav; Krishna Kamal Kumar

doi:10.5750/ijme.v168iA3(S).1957

Published: Oct 7, 2026

DOI: https://doi.org/10.5750/ijme.v168iA3(S).1957

Keywords:

Finite element analysis Thermal modelling Surface Roughness (Ra) Material removal rate EDM-drilling Numerical simulation Optimization

Brajesh Kumar Lodhi

Assistant Professor, Mechanical Engineering Department, IET, Bundelkhand University, Jhansi (U.P.), India

Rohit Sahu

G.L. Bajaj Institute of Technology and Management, Greater Noida, India

Dr. Vinod D. Golakiya

Associate Professor, Mechanical Engineering Department, Government Engineering College, Surat, Gujarat, India

Dr. Tushar P Gundarneeya

Associate Professor, Mechanical Engineering Department, Government Engineering College, Surat, Gujarat, India

Yogesh Dinkar Jadhav

Department of Mechanical Engineering, Sinhgad College of Engineering, Savitribai Phule Pune University, Pune, Maharashtra, India

Krishna Kamal Kumar

Student, Mechanical Engineering Department, IET, Bundelkhand University, Jhansi (U.P.), India

Abstract

Electrical Discharge Machining (EDM) is a high-precision, non-conventional machining process widely used to produce intricate geometries in biomedical and aerospace components. It is particularly effective for fabricating micro-holes, complex shapes, and achieving high dimensional accuracy in difficult-to-machine materials such as aluminum-based (Al-SiC) composites. To optimize EDM performance for precise microchannel fabrication, the influence of key process parameters must be systematically analyzed. In this study, material removal rate (MRR) and surface roughness (Ra) were considered as performance responses, while duty cycle, discharge current (Ip), and pulse-on time (T_on) were selected as input variables. A finite element method (FEM)-based model was developed to analyze the transient thermal behaviour during EDM drilling. The model employs a 2D axisymmetric domain and incorporates varying discharge current and pulse-on time conditions. The results demonstrate that the developed model effectively predicts thermal distribution and supports optimization of EDM parameters for improved machining performance.

Issue

Vol. 168 No. A3(S) (2026): Special Issue - Smart and Sustainable Material for Marine Engineering Applications

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