The paper deals with a solution to increase the machining rate at electrical discharge machining aided by ultrasonics (EDM+US), i.e. the overlapping the voltage pulses provided by EDM generator on the cumulative microjets stage (CMS), which occurs at every final of an ultrasonic period by collective implosion of the gas bubbles from the working gap. This overlapping moves the limit of the removed material by a discharge from the boiling isothermal (at classic EDM) to melting isothermal (at EDM+US) as it is emphasized by the results of finite element analysis. The preliminary experimental data analyzed in the paper are obtained in case of random overlapping at ultrasonic frequency of 20 kHz. They demonstrate an increase of machining rate with more than 300% at EDM+US in comparison with classic EDM in the same working conditions.
The paper deals with finite element modelling (FEM) of the process of micro-electrical discharge machining of micro-holes aided by ultrasonic longitudinal oscillations of workpiece (μEDM+US). FEM of the process comprises two components: the thermal one due to μEDM removal mechanism, and the ultrasonic one caused by cavitation effect generated inside the lateral working gap. The FEM results obtained are validated by experimental data in terms of craters dimensions produced by single discharges, leading to optimization strategy of process parameters.
The paper deals with design, modelling, and testing of an ultrasonic (US) chain with torsional vibrations that includes a tool at its end and could be used for different industrial applications such conventional and nonconventional machining of revolution, helicoidal, and curved surfaces or various types of materials. The US chain includes a horn with helicoidal channel whose profile was studied aiming at growing the amplification of amplitude of the tool, positioned in an antinode point. After the shape design of US horn, finite element analysis was applied to simulate the torsional vibrations of the horn and integrated tool with highest amplitude. Some experiments were made at electrical discharge machining (EDM) aided by torsional ultrasonic vibrations. The results emphasized the technological parameters improvement like machining rate increase and surface roughness decrease, compared to usual EDM without US.
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