Skip to main content
SpringerLink
Log in

The effect of ultrasonic amplitude on the performance of ultrasonic vibration-assisted EDM micro-hole machining

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

A study on ultrasonic vibration-assisted electrical discharge machining (UVEDM) micro-hole, which mainly includes three key designs, was conducted to improve the machining performance of the electric discharge machining (EDM) micro-holes on TC4 titanium alloy. First, a mathematical model for the velocity of the flow field in the interelectrode gap was established. Consequently, the effect of the presence or absence of ultrasonic vibration on the flow velocity was analyzed. Furthermore, based on COMSOL Multiphysics, the two distributions of the flow field and the debris in the interelectrode gap were simulated, and the influence of ultrasonic amplitude on them was analyzed. Finally, the study of UVEDM micro-hole machining with different ultrasonic amplitudes was conducted. The machining performance of the UVEDM micro-hole was found to increase with the increment of the ultrasonic amplitude and the optimal value of 5.22 μm, while the performance decreases when the ultrasonic amplitude goes beyond the optimal value. Compared with EDM micro-hole, the MMR is increased by 2.4 times, and the electrode loss and hole taper are reduced by 56% and 24%, respectively.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

References

  1. Li ZK, Tang JJ, Li YS, Bai JC (2022) Investigation on surface integrity in novel micro-EDM with two-dimensional ultrasonic circular vibration (UCV) electrode. J Manuf Process 76:828–840. https://doi.org/10.1016/j.jmapro.2022.03.004

  2. Rajhi W, Alatawi I, Subhani T, Ayadi B, Al-Ghamdi A, Khaliq A (2021) A contribution to numerical prediction of surface damage and residual stresses on die-sinking EDM of Ti6Al4V. J Manuf Process 68:1458–1484. https://doi.org/10.1016/j.jmapro.2021.06.056

    Article  Google Scholar 

  3. Goiogana M, Sarasua JA, Ramos JM (2018) Ultrasonic assisted electrical discharge machining for high aspect ratio blind holes. Procedia CIRP 68:81–85. https://doi.org/10.1016/j.procir.2017.12.026

    Article  Google Scholar 

  4. Jain S, Parashar V (2021) Critical review on the impact of EDM process on biomedical materials. Mater Manuf Processes 36(15):1701–1724. https://doi.org/10.1080/10426914.2021.1942907

    Article  Google Scholar 

  5. Abu Qudeiri J, Saleh A, Ziout A, Mourad A, Abidi M, Elkaseer A (2019) Advanced electric discharge machining of stainless steels: assessment of the state of the art, gaps and future prospect. Materials12(6). https://doi.org/10.3390/ma12060907

  6. Singh P, Yadava V, Narayan A (2018) Machining performance characteristics of Inconel 718 superalloy due to hole-sinking ultrasonic assisted Micro-EDM (2018). J Adv Manuf Syst 17(01):89–105. https://doi.org/10.1142/S0219686718500063

  7. Zhao W, Wang Z, Di S, Chi G, Wei H (2018) Ultrasonic and electric discharge machining to deep and small hole on titanium alloy. J Mater Process Tech 120(1–3):101–106. https://doi.org/10.1016/S0924-0136(01)01149-9

  8. Hung JC, Lin JK, Yan BH, Liu, HS, Ho, PH (2006) Using a helical micro-tool in micro-EDM combined with ultrasonic vibration for micro-hole machining. J Micromech Microeng (16):2705–2713. https://doi.org/10.1088/0960-1317/16/12/025

  9. Yu ZY, Zhang Y, Li J, Zhao F, Guo D (2009) High aspect ratio micro-hole drilling aided with ultrasonic vibration and planetary movement of electrode by micro-EDM. CIRP Annal-Manuf Technol 58(1):213–216. https://doi.org/10.1016/j.cirp.2009.03.111

  10. Xing Q, Yao Z, Zhang Q (2021) Effects of processing parameters on processing performances of ultrasonic vibration-assisted micro-EDM. Int J Adv Manuf Technol 112(10):1–16. https://doi.org/10.1007/s00170-020-06357-9

  11. Liu Y, Chang H, Zhang W, Ma, FJ, Sha ZH, Zhang SF (2018) A simulation study of debris removal process in ultrasonic vibration-assisted electrical discharge machining (EDM) of deep holes. Micromachines 9(8). https://doi.org/10.3390/mi9080378

  12. Li ZK, Tang JJ, Bai JC (2020) A novel micro-EDM method to improve microhole machining performances using ultrasonic circular vibration (UCV) electrode. Int J Mech Sci 175. https://doi.org/10.1016/j.ijmecsci.2020.105574

  13. Mastud S, Kothari NS, Singh RK, Joshi, SS (2015) Modeling debris motion in vibration-assisted reverse micro electrical discharge machining process (R-MEDM). J Microelectromech Syst 24(3): 661–676. https://doi.org/10.1109/JMEMS.2014.2343227

  14. Zhang Y, Xie B (2021) Investigation on hole diameter non-uniformity of hole arrays by ultrasonic vibration-assisted EDM. Int J Adv Manuf Technol (2). https://doi.org/10.1007/s00170-021-06597-3

  15. Liang ZQ, Zeng LW (2002) Hydromechanics. Chongqing University Press, Chongqing, China

    Google Scholar 

  16. Okada A, Uno Y, Onoda S, Habib S (2009) Computational fluid dynamics analysis of working fluid flow and debris movement in wire EDMed kerf. CIRP Annal - Manuf Technol 58(1):209–212. https://doi.org/10.1016/j.cirp.2009.03.003

  17. Huang H, Zhang H, Zhou L, Zheng, HY (2003) Ultrasonic vibration-assisted electro-discharge machining of microholes in Nitinol. J Micromech Microeng 13(5):693–700. https://doi.org/10.1088/0960-1317/13/5/322

  18. Dong Y, Li G, Wang Y, Song, JB, Yang, S, Yu, HY (2021) Study on the effective discharge energy mechanism of vertical ultrasonic vibration-assisted EDM processing.Proc Ins Mech Eng Part B J Eng Manuf. https://doi.org/10.1177/09544054211028527

  19. Gao CS, Liu ZX (2003) A study of ultrasonically aided micro-electrical-discharge machining by the application of workpiece vibration. J Mater Proc Tech 139(1–3): 226–228. https://doi.org/10.1016/S0924-0136(03)00224-3

Download references

Funding

Financial support for this work provided by the National Natural Science Foundation of China (grant no. 51905363), the Natural Science Foundation of Jiangsu Province (grant no. BK20190940 & No. BK20210866), the Natural Science Foundation of the Jiangsu Higher Education Institutions of China (grant no. 19KJB460008 & No. 21KJB460021), the China Postdoctoral Science Foundation (grant no. 2019M661914).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Suzhou University of Science and Technology, Suzhou, 215009, China

    Peng Zhang, Zhen Yin, Chenwei Dai, Ziyang Cao, Qing Miao & Kun Zhang

  2. Suzhou Key Laboratory of Precision and Efficient Machining Technology, Suzhou University of Science and Technology, Suzhou, 215009, China

    Zhen Yin, Chenwei Dai, Ziyang Cao & Qing Miao

Authors
  1. Peng Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhen Yin
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Chenwei Dai
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Ziyang Cao
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Qing Miao
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Kun Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All the authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Peng Zhang. The first draft of the manuscript was written by Peng Zhang, and all the authors commented on previous versions of the manuscript. All the authors read and approved the final manuscript.

Corresponding author

Correspondence to Zhen Yin.

Ethics declarations

Consent to participate

It is confirmed that all the authors are aware and satisfied of the authorship order and correspondence of the paper.

Consent for publication

The publisher has the permission of the authors to publish the given article.

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, P., Yin, Z., Dai, C. et al. The effect of ultrasonic amplitude on the performance of ultrasonic vibration-assisted EDM micro-hole machining. Int J Adv Manuf Technol 122, 1513–1524 (2022). https://doi.org/10.1007/s00170-022-09852-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-09852-3

Keywords

Search

Navigation