Thermo-Mechanical Modeling And Residual Stress Analysis In WEDM Of Ti-6Al-4V ELI Using Python-Based Computational Framework

Abstract

This study comprise of a comprehensive computational framework is developed using Python programming to simulate the residual stress distribution and phase transformation behavior in Wire Electrical Discharge Machining (WEDM) of Ti-6Al-4V ELI alloy. The proposed model integrates dynamic spark energy input, heat conduction, thermo-mechanical coupling, and phase kinetics to capture the complex interplay of thermal, metallurgical, and mechanical phenomena that define surface integrity in WEDM. A multi-physics, time-dependent approach is adopted, accounting for rapid melting and quenching cycles, latent heat effects, thermal dilation, and microstructural evolution, including martensitic (α′) and ω-phase transformations. A multi-spark thermal model is employed to realistically simulate dynamic discharge behavior and predict heat deposition. The framework solves the transient heat conduction equation coupled with convective and radiative boundary conditions, phase transformation kinetics, and residual stress evolution by considering thermal stress, transformation-induced stress, plastic deformation, and volumetric strain effects. Material properties, including temperature-dependent thermal and mechanical characteristics, are incorporated into the simulation for high-fidelity modeling. The proposed computational approach provides a physics-based understanding of residual stress generation in WEDM at high, medium, and low energy levels, enabling improved control over residual stresses and microstructural properties in precision manufacturing of Ti-6Al-4V ELI components.