OBRABOTKAMETALLOV Vol. 24 No. 2 2022 37 TECHNOLOGY Theoretical simulation of the process interelectrode space fl ushing during copy-piercing EDM of products made of polymer composite materials Evgeniy Shlykov a, *, Timur Ablyaz b, Karim Muratov c Perm National Research Polytechnic University, 29 Komsomolsky prospekt, Perm, 614990, Russian Federation a https://orcid.org/0000-0001-8076-0509, Kruspert@mail.ru, b https://orcid.org/0000-0001-6607-4692, lowrider11-13-11@mail.ru, c https://orcid.org/0000-0001-7612-8025, Karimur_80@mail.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2022 vol. 24 no. 2 pp. 25–38 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2022-24.2-25-38 ART I CLE I NFO Article history: Received: 31 March 2022 Revised: 06 April 2022 Accepted: 12 April 2022 Available online: 15 June 2022 Keywords: Polymer composite materials Copy-piercing electrical discharge machining Flushing Sludge Funding The work was supported by the grant of the President of the Russian Federation for state support of young Russian scientists – candidates of sciences No. MK-566.2021.4. Acknowledgements Research were partially conducted at core facility “Structure, mechanical and physical properties of materials”. ABSTRACT Introduction. Polymer composite materials (PCM) are used to improve the mechanical properties and increase the working period of products. For the processing of products made of PCM, the use of electrophysical processing methods is standard. One of these methods is copy-piercing electrical discharge machining (EDM). The use of such methods for processing PCM is due to its high physical and mechanical characteristics and the complexity of processing by blade methods. Considering the fact that the PCM element is a binder – epoxy resin, which is destroyed at the edges of the resulting holes and grooves during EDM, PCM can be considered diffi cult to process. During the EDM of holes in PCM products, the temperature rises, and ineffi cient cooling often occurs in the processing zone. The paper is devoted to theoretical simulation in the Ansys package, which makes it possible to evaluate the impact of fl ushing method on the effi ciency of the EDM of PCM products based on numerical simulation in fi nite element analysis software systems. The aim of the work is to increase the productivity of the processes of EDM for PCM products. Methods. Experimental studies were carried out according to the method of a classical experiment on a copy-piercing electrical discharge Smart CNC machine. The workpiece was processed at a constant voltage U = 50 V, pulse on-time Ton = 100 μs and current: I = 10 A. For theoretical simulation of the fl ow, the ANSYS CFX 20.1 software was used. Flow distribution simulation was carried out at three processing depths (2, 10, 15 mm), as well as at three nozzle inclination angles (15, 45, 75°). Results And Discussion. The analysis of the data obtained showed that in the case of the EDM of PCM, the angle of the location of the fl ushing nozzles should be taken into account in order to increase the productivity of processing deep, blind holes. It is established that the highest performance value is achieved when the nozzles are located at an angle of 15˚. The laminar motion prevails. With this arrangement of the nozzles, the value of the liquid pressure and the removal of the sludge are stable both with the EDM of PCM to a depth of 2 mm, and when processing to a depth of 15 mm. It is noted that for processing holes with a depth of 10 mm or more, it is worth considering the angle of inclination of the fl ushing nozzle for effective processing, it is necessary to remove eroded particles from the gap. In the process of conducting an experimental study, when processing holes with a depth of 15 mm, sticking of sludge to the electrode-tool was observed, as well as the closure of the EDM process, the occurrence of secondary discharges in the processing zone, which caused the processing to stop. For citation: Shlykov E.S., Ablyaz T.R., Muratov K.R. Theoretical simulation of the process interelectrode space fl ushing during copypiercing EDM of products made of polymer composite materials. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2022, vol. 24, no. 2, pp. 25–38. DOI: 10.17212/1994-6309-2022-24.2-25-38. (In Russian). ______ * Corresponding author Shlykov Evgeniy S., Ph.D. (Engineering), Associate Professor Perm National Research Polytechnic University 29 Komsomolsky prospect 614990, Perm, Russian Federation Tel.: 8 (342) 2-198-324, e-mail: Kruspert@mail.ru References 1. Sarde B., Patil Y.D. 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