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Investigation on hole diameter non-uniformity of hole arrays by ultrasonic vibration-assisted EDM

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Abstract

Ultrasonic vibration-assisted electrical discharge machining (EDM) as an alternative advanced processing technology has been widely used to machine micro-hole arrays. However, there exists a concentration of debris particles in the discharge gap, which affects the machining accuracy of micro-hole arrays by ultrasonic vibration-assisted EDM with tool electrode arrays. In this study, a series of experiments of ultrasonic vibration-assisted EDM of micro-hole arrays with tool electrode arrays were performed, and the experimental results demonstrate that the hole diameter in the central holes of hole arrays is a little bigger than those in the peripheral holes of hole arrays. To illustrate the mechanism of hole diameter non-uniformity of micro-hole arrays by ultrasonic vibration-assisted EDM with tool electrode arrays, a three-dimensional gap flow field model for ultrasonic vibration-assisted EDM of micro-hole arrays was proposed based on computational fluid mechanics. In the flow field model, the laws of flow field velocity and debris particles distribution were simulated numerically under the effect of ultrasonic vibration. To investigate the rules of flow field velocity and debris particles distribution during ultrasonic vibration-assisted EDM of micro-hole arrays, the flow field model of 3 × 3 micro-hole arrays, 5 × 5 micro-hole arrays, and 10 × 10 micro-hole arrays were considered. The numerical simulation results show that in the flow field, the concentration degree of debris particles in the peripheral holes of micro-hole arrays is lower than those of the central holes of micro-hole arrays. The non-uniformity distribution of debris particles of the central holes and the peripheral holes of micro-hole arrays strength the local electric field and leads to non-uniformity of discharge breakdown probability, which causes the hole diameter non-uniformity of micro-hole arrays by ultrasonic vibration-assisted EDM. The experimental and numerical simulation results reveal the mechanism of hole diameter non-uniformity of micro-hole arrays by ultrasonic vibration-assisted EDM with tool electrode arrays and suggest that decreasing the concentration of debris particles is the effective way to improve the performance of EDM of micro-hole arrays.

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Funding

This research was funded by the National Natural Science Foundation of China (NSFC) (No.51605123).

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Authors and Affiliations

  1. Key Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science and Technology, Harbin, 150080, China

    Yuan Zhang & Baocheng Xie

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  1. Yuan Zhang
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  2. Baocheng Xie
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Conceived of the presented idea, B.X.; Y.Z. and B.X. discussed the results and contributed to the final manuscript; B.X. wrote the manuscript with support from Y.Z. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Baocheng Xie.

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Zhang, Y., Xie, B. Investigation on hole diameter non-uniformity of hole arrays by ultrasonic vibration-assisted EDM. Int J Adv Manuf Technol 112, 3083–3091 (2021). https://doi.org/10.1007/s00170-021-06597-3

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