Finite elements analysis of cylindrical copper shelled SLA electrodes

Abstract

A cylindrical copper shelled SLA electrode was modelled and analysed using the finite element method. The thickness of the silver paint is assumed to be uniform and constant around the SLA epoxy core with a value of 15 μm.The copper shell thickness was set at 0.3 mm and was considered constant around the silver painted surface too. Due to the axissymmetric shape, a 2-D analysis was used, and simulations under steady state and transient die sink EDMing conditions were followed. The static thermo-mechanical finite element analysis clearly showed the mechanical behaviour of copper shelled SLA electrodes. It was found that the results are affected by the silver paint layer thickness. Heat flow channels modify the temperature field and relaxation notches could improve the stress distribution. © 2010 Taylor & Francis Group.