Effects of processing parameters on processing performances of ultrasonic vibration-assisted micro-EDM
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ORIGINAL ARTICLE
Effects of processing parameters on processing performances of ultrasonic vibration-assisted micro-EDM Qixuan Xing 1,2 & Zhenyang Yao 1,2 & Qinhe Zhang 1,2 Received: 2 July 2020 / Accepted: 4 November 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract To improve the processing efficiency and precision of micro-holes with a large depth-to-diameter ratio on titanium alloy, ultrasonic vibration-assisted micro-electrical discharge machining (micro-EDM) is adopted. It could improve the effective discharge ratio in the machining process and promote the removal of erosion products. Compared with the non-ultrasonic vibration-assisted micro-EDM machining of a large depth-to-diameter ratio on titanium alloy, when the ultrasonic amplitude was 6 μm, material removal rate (MRR) was increased by 2.4 times, relative tool wear rate (RTWR) was reduced by 65.8%, taper angle (θ) was reduced by 73%, and overcut (OC) was reduced by 32%. Based on the single factor experiment, this paper studied the influence rule and mechanism of processing parameters (pulse width, pulse interval, peak current, and ultrasonic amplitude) on the machining effect. Then, based on the orthogonal experiment, the optimization research on the processing technology of ultrasonic vibration-assisted micro-EDM was studied. The optimal processing parameter combination of MRR, RTWR, θ, and OC was obtained by signal-noise ratio (SNR) analysis. And regression analysis and analysis of variance were performed on the results, and the process models of ultrasonic vibration-assisted micro-EDM were established. The verification experiment proved the reliability of the single objective optimization result and the process model. Keywords Micro-EDM . Ultrasonic vibration system . Processing parameters . Signal-noise ratio . Single objective optimization . Process model
1 Introduction At present, products have begun to develop towards miniaturization, integration, and intelligence. Micro-machinery will be more and more widely used in industry and agriculture, environment, information engineering, biomedicine, aerospace, national defense, and other fields [1–5]. Micro-EDM is a machining technology which uses the electro corrosion of micropulse discharge to remove redundant metals [6, 7]. MicroEDM is often used in the machining of TC4 titanium alloy and other difficulty processing materials [8, 9].
* Qinhe Zhang [email protected] 1
Key Laboratory of High Efficiency and Clean Mechanical Manufacture (Ministry of Education), School of Mechanical Engineering, Shandong University, Jinan 250061, People’s Republic of China
2
National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan 250061, China
When micro-EDM processes micro-holes with a large depth-to-diameter ratio on the difficulty processing material, debris is not easily removed and tends to accumulate at the bottom of the micro-hole [10, 11]. In the process of machining, abnormal discharge phenomena such as secondary discharge, arcin
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