Expanding heat source model for thermal spalling of TiB₂ in electrical discharge machining

A model is presented to explain the recently reported mechanism of thermal spalling for shaping high melting point ceramics by electrical discharge machining. Since previous models fail to explain the experimental observations completely, an expanding circular heat source created by growth of plasma is assumed to act on the surface. Erosion of materials by spalling is caused by thermally induced compressive stresses during heating-up periods and tensile stresses during cooling-down periods. This model explains material removal for anodic erosion in general (wire-cutting machines) and for cathodic erosion (die-sinking machines) whenever long pulse duration is used. Simulation of the model for TiB₂ provides a local melt front that penetrates to a depth of submicrometer, then recedes as pulse duration increases. Spalling develops flakes with thickness correlated to pulse duration. The results were verified by the experimental observations which showed that large flakes having the predicted maximum thickness as well as few quenched spherical droplets containing titanium were obtained.