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Effect of cavitation on surface formation mechanism of ultrasonic vibration-assisted EDM

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Abstract

Compared with traditional EDM, ultrasonic vibration-assisted electric discharge machining (UEDM) technology provides excellent machining results for difficult-to-machine materials. There are many factors influencing the material processing. Ultrasonic cavitation bubble collapse has a big impact on UEDM processing. In this study, the influences of shock wave, high temperature, and pressure environment generated by collapse of cavitation bubble on workpiece surface are analyzed. The outer wall movement model of cavitation bubble under ultrasonic action is derived based on the Rayleigh-Plesset bubble dynamics equation. The effect of individual cavitation bubble from the initial state to collapse is simulated in order to reveal the changing trend of surface quality. According to the analysis of experimental and simulation results, it is found that the surface quality of EDM workpiece with ultrasonic cavitation effect is better than that of ordinary EDM. After the addition of ultrasonic, the surface roughness value of the workpiece is reduced by 9.3%–27.9%, while the ultrasonic cavitation effect reduces the surface roughness value of the workpiece by about 17.0%.

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All data generated or analyzed during this study are included in this published article.

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Funding

This work supported by the Natural Science Foundation of Tianjin City (18JCQNJC05200) and Tianjin Municipal Education Commission (2018KJ116).

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Authors and Affiliations

  1. College of Mechanical Engineering, Tianjin University of Science and Technology, Tianjin, 300457, China

    Yan Wang, Lingfeng Fan, Jian Shi & Yinghuai Dong

  2. School of Light Industry Science and Engineering, Tianjin University of Science and Technology, Tianjin, 300457, China

    Zhiqiang Fu

Authors
  1. Yan Wang
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  2. Lingfeng Fan
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  3. Jian Shi
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  4. Yinghuai Dong
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Yan Wang, Lingfeng Fan, Jian Shi, Yinghuai Dong, and Zhiqiang Fu. The first draft of the manuscript was written by Lingfeng Fan, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Yinghuai Dong.

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Wang, Y., Fan, L., Shi, J. et al. Effect of cavitation on surface formation mechanism of ultrasonic vibration-assisted EDM. Int J Adv Manuf Technol 124, 3645–3656 (2023). https://doi.org/10.1007/s00170-022-10780-5

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  • DOI: https://doi.org/10.1007/s00170-022-10780-5

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