When machining a small hole with high aspect ratio in EDM, it is hard for the flushing liquid entering the bottom gap and the debris could hardly be removed, which results in the accumulation of debris and affects the machining efficiency and machining accuracy. The assisted ultrasonic vibration can improve the removal of debris in the gap. Based on dynamics simulation software, Fluent, a three-dimensional (3D) model of debris movement in the gap flow field of EDM small hole machining assisted with side flushing and ultrasonic vibration is established in this paper. The laws of different amplitudes and frequencies and different aspect ratios on debris distribution and movement are quantitatively analyzed. The motion height of debris was observed under different conditions. The research results show that periodic ultrasonic vibration can promote the movement of debris, which is beneficial to the removal of debris in the machining gap. When compared to traditional small hole machining in EDM, the debris in the machining gap were greatly reduced, which ensures the stability of the machining process and improves the machining efficiency.
High precision stretch bending of aluminum alloy profile is the key technology for making car’s frame body. A numerical simulation study on the displacement-controlled process for a typical kind of L-section aluminum alloy profile used in high-speed rail with finite element analysis software is presented. The effect of different friction coefficients, with or without baffle and cover plate on the equivalent stress,strain and cross-sectional distortion are investigated. It is shown that the increase of the friction coefficient can increase the cross-sectional distortion, equivalent stress and strain. The installation of baffle and cover plate can significantly reduce the cross-sectional distortion in the middle section of the profile, and increase the equivalent stress and strain to some extent.
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