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Research on ultrasonic vibration–assisted micro-EDM milling of microgrooves with large aspect ratio

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Abstract

For the purpose of improving the machining efficiency and quality of microgrooves with a large aspect ratio on titanium alloy, ultrasonic vibration–assisted micro-electrical discharge machining (micro-EDM) is employed. It can greatly reduce the occurrence of abnormal discharges and increase the valid discharge ratio during the processing so that large aspect ratio microgrooves can be obtained more efficiently. Based on the theory of the ultrasonic vibration system, this research carried out the selection of the ultrasonic generator, the design of the ultrasonic transducer, and the design of the ultrasonic horn. The amplitude and frequency tests of the ultrasonic vibration system had verified the effectiveness of the ultrasonic vibration system. Finally, on the foundation of the single factor experiment, the present research explored the influence of processing parameters (pulse width, pulse interval, peak current, and ultrasonic amplitude) on the material removal rate (MRR), relative tool wear rate (RTWR), and surface roughness (Ra) and proved the effectiveness of additional ultrasonic vibration in improving the machining efficiency and surface quality of microgrooves with a large aspect ratio on titanium alloy.

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Abbreviations

T :

Stress on the section (N)

F :

Force acting on the rod (N)

S(x):

Area function of any section

E :

Elastic modulus of the rod (Pa)

l :

Displacement function of the mass point

ρ :

Density of the material (kg/m3)

C :

Length of deformation of the material per second (m/s)

ω :

Angular frequency (rad/s)

k :

Circular wavenumber

Z :

Characteristic impedance (kg/(m2 s))

L :

Length of component (m)

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Funding

This work was supported by the National Natural Science Foundation of China under Grant (No. 51775316).

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Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture (Ministry of Education), School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Qixuan Xing, Minghao Gao, Zhenyang Yao & Qinhe Zhang

  2. National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan, 250061, China

    Qixuan Xing, Minghao Gao, Zhenyang Yao & Qinhe Zhang

Authors
  1. Qixuan Xing
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  2. Minghao Gao
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  3. Zhenyang Yao
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  4. Qinhe Zhang
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Contributions

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

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Correspondence to Qinhe Zhang.

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Xing, Q., Gao, M., Yao, Z. et al. Research on ultrasonic vibration–assisted micro-EDM milling of microgrooves with large aspect ratio. Int J Adv Manuf Technol 128, 1629–1639 (2023). https://doi.org/10.1007/s00170-023-11984-z

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  • DOI: https://doi.org/10.1007/s00170-023-11984-z

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