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Experimental research and multi-objective optimization of ultrasonic vibration–assisted EDM for Ti6Al4V micro-holes

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Abstract

Ultrasonic vibration–assisted electrical discharge machining (UEDM) was studied to improve the machining performance for TC4 micro-holes. First, a computational fluid dynamic (CFD) model of inter-electrode gap for the micro-hole was established using COMSOL Multiphysics, and the effect of ultrasonic amplitude on the distribution of fluid and debris in the inter-electrode gap was analyzed. The experimental study of UEDM for machining performance of TC4 micro-hole under different machining parameters was conducted by using the controlled variable method. Results showed that the ultrasonic vibration of the electrode is beneficial to improve the machining performance for micro-hole. Under the optimal processing parameters, the material removal rate is improved four times, and RTWR and θ are reduced by about 50%. Finally, the neural network and genetic algorithm were used to predict and optimize the experimental results. The average error is 4.1% between the optimal processing parameters [Xn] obtained by the above method and from the experiment.

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Data will be made available on request.

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Funding

The authors received financial support for this work from the National Natural Science Foundation of China (grant no. 51905363), the Natural Science Foundation of Jiangsu Province (grant no. BK20190940), and the China Postdoctoral Science Foundation (grant no. 2019M661914).

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Authors and Affiliations

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

    Peng Zhang, Zhen Yin, Chenwei Dai & Kun Zhang

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

    Zhen Yin

  3. School of Mechanical Engineering, North University of China, Taiyuan, 030051, China

    Daguo Yu & Xingquan Shen

  4. School of Mechanical Engineering, Taiyuan University of Technology, Taiyuan, 030051, China

    Yanqing Wang

Authors
  1. Peng Zhang
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  2. Zhen Yin
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Contributions

Peng Zhang: data curation, investigation, writing—original draft, writing—review and editing. Zhen Yin, Daguo Yu, Xingquan Shen, and Yanqing Wang: funding acquisition, methodology, project administration, supervision. Chenwei Dai and Kun Zhang: validation.

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Correspondence to Zhen Yin.

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Zhang, P., Yin, Z., Yu, D. et al. Experimental research and multi-objective optimization of ultrasonic vibration–assisted EDM for Ti6Al4V micro-holes. Int J Adv Manuf Technol 127, 3413–3425 (2023). https://doi.org/10.1007/s00170-023-11641-5

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