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Analysis of material removal and surface generation mechanism of ultrasonic vibration–assisted EDM

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Abstract

Ultrasonic vibration–assisted EDM (UEDM) has excellent performance on difficult-to-machine materials processing such as titanium alloy, stellite, and nickel-based alloy, and it was hard to describe the material removal process and surface generation mechanism due to the complex physiochemical reactions during UEDM. In the present study, the material removal mechanism is fundamentally studied based on heat transfer theory. The model of microscopic removal volume of single pulse in UEDM is established according to the characteristics of EDM removal mechanism and the interference of ultrasonic vibration energy. The micro-surface topography generating process is described and the influence of ultrasonic vibration on the machined surface is analyzed. Both simulation calculation and experiment validation are executed in order to verify the accuracy of the theoretical derivation. As the experimental results have shown, the surface-generating process is matching well with the theoretical deduction; the carbon deposit area is reduced and the surface roughness is decreased due to the ultrasonic vibration interference. The machined surface quality can be modified by adjusting the matching performance of ultrasonic vibration energy and EDM energy.

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Acknowledgments

The authors appreciate the support of Tianjin Natural Science Foundation (grant no. 18JCQNJC05200) and Tianjin Municipal Education Commission Scientific Research Project (grant no. 2018KJ116).

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Authors and Affiliations

  1. Tianjin University of Science and Technology, Tianjin, China

    Yan Wang, Zhiqiang Liu, Jian Shi, Yinghuai Dong & Shuo Yang

  2. Tianjin Key Laboratory of Integrated Design and On-line Monitoring for Light Industry & Food Machinery and Equipment, Tianjin, China

    Yan Wang, Yinghuai Dong & Shuo Yang

  3. Key Laboratory of Advanced Ceramics and Machining Technology, Ministry of Education, Tianjin University, Tianjin, China

    Xiaofeng Zhang & Bin Lin

Authors
  1. Yan Wang
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  2. Zhiqiang Liu
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  3. Jian Shi
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  4. Yinghuai Dong
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  5. Shuo Yang
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  6. Xiaofeng Zhang
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  7. Bin Lin
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Correspondence to Yinghuai Dong.

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Wang, Y., Liu, Z., Shi, J. et al. Analysis of material removal and surface generation mechanism of ultrasonic vibration–assisted EDM. Int J Adv Manuf Technol 110, 177–189 (2020). https://doi.org/10.1007/s00170-020-05769-x

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  • DOI: https://doi.org/10.1007/s00170-020-05769-x

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