| Summary: | Beryllium copper alloy has high strength, nonmagnetic, good wear resistance, corrosion resistance, high fatigue strength and non-sparking qualities. These properties impose machining issues when machined by conventional machining processes. Electric discharge machining is a practically viable solution to machine such materials. Recently researchers have been attracted by powder mixed electric discharge machining with the advancement in technology. Present study focuses on developing Finite Element model of Powder Mixed Electric Discharge Machining of Beryllium copper alloy with experimental validation. An axis symmetric three-dimensional model has been developed and simulated using ANSYS 15.0 software for obtaining the temperature distribution on the surface of workpiece during a single discharge machining process. And the temperature profile was utilized to estimate the material removal rate. Experiments were performed to validate the numerical results. The average percentage error of 7.8% was obtained between numerical and experimental results. Thus, a good agreement between the experimental and numerical results shows that the software model can efficiently simulate and predict the real time results. Keywords: BeCu alloys, Thermal transient analysis, Material removal rate, ANSYS, Powder mixed EDM
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