Ultrasonic Vibration Assisted Electrical Discharge Machining and Micro-Electrical Discharge Machining: A Review

IF 2.7 4区工程技术 Q2 ENGINEERING, MANUFACTURING Machining Science and Technology Pub Date : 2023-10-15 DOI:10.1080/10910344.2023.2263780

Ibrahem Maher, Hassan El-Hofy, Mohamed H. El-Hofy

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引用次数: 1

Abstract

AbstractMaterial is removed during electrical discharge machining (EDM) because of the high temperatures. Hence, tiny components of the tool and workpiece melt and evaporate, causing molten metal to solidify and form debris. This debris affects process efficiency if not flushed out. To ensure continuous flushing, tools, workpiece or dielectric motion are necessary. Introducing ultrasonic vibrational motion to the tool, workpiece or the dielectric liquid became a viable alternative for the evacuation of debris during the ultrasonic assisted electrical discharge machining (USEDM) and ultrasonic assisted micro-electrical discharge machining (USµEDM) processes. In addition to the US vibration, powder mixed to the dielectric medium, using gas as a dielectric medium, and adopting the magnetic field (MF) assistance in USEDM are additional attempts to improve the performance of these processes. This article reviews the main research directions, process parameters and performance indicators of USEDM and USµEDM processes. Extra enhancement to their performance using powder mixing, gas or MF assistance was also presented. Numerous modeling and optimization methods have also been examined. The study demonstrated the benefits of using US vibration assistance to EDM and micro-electrical discharge machining regarding a faster material removal rate, improved surface quality and decreased electrode wear rate. Finally, the current article identifies potential directions for future studies.Keywords: AmplitudeEDMfrequencymagnetic fieldmaterial removal ratenano-powdersurface roughnesstool wearultrasonicvibration Author contributionsNot applicable.Ethical approval statementNot applicable.Consent formNot applicable.Consent for publicationNot applicable.Disclosure statementThe authors declare no conflict of interest.Data availability statementNot applicable.Code availability statementNot applicable.Additional informationFundingThis work received no specific grant from any funding agency in the public, commercial or not-for-profit sectors.

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超声振动辅助电火花加工与微细电火花加工综述

摘要在电火花加工(EDM)过程中，由于温度高，材料被去除。因此，工具和工件的微小部件熔化并蒸发，导致熔融金属凝固并形成碎片。这些碎片如果不清除，会影响工艺效率。为了确保连续的冲洗，工具、工件或介质运动是必要的。在超声辅助电火花加工(USEDM)和超声辅助微电火花加工(USµEDM)过程中，将超声振动运动引入工具、工件或介电液体成为清除碎屑的可行替代方案。除了US振动之外，粉末混合到介电介质中，使用气体作为介电介质，以及在USEDM中采用磁场(MF)辅助是提高这些工艺性能的额外尝试。本文综述了USEDM和USµEDM工艺的主要研究方向、工艺参数和性能指标。还介绍了使用粉末混合、气体或MF辅助来额外增强其性能的方法。还研究了许多建模和优化方法。该研究证明了使用美国振动辅助电火花加工和微电放电加工的好处，包括更快的材料去除率，改善表面质量和降低电极磨损率。最后，本文指出了未来研究的潜在方向。关键词:振幅高频磁场材料去除速率纳米粉末表面粗糙度磨耗超声振动作者贡献不适用伦理批准声明不适用。同意书不适用。发表同意不适用。声明作者声明无利益冲突。数据可用性声明不适用。代码可用性声明不适用。本研究未获得任何公共、商业或非营利机构的资助。

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来源期刊

Machining Science and Technology 工程技术-材料科学：综合

CiteScore

5.70

自引率

3.70%

发文量

审稿时长

6 months

期刊介绍： Machining Science and Technology publishes original scientific and technical papers and review articles on topics related to traditional and nontraditional machining processes performed on all materials—metals and advanced alloys, polymers, ceramics, composites, and biomaterials. Topics covered include: -machining performance of all materials, including lightweight materials- coated and special cutting tools: design and machining performance evaluation- predictive models for machining performance and optimization, including machining dynamics- measurement and analysis of machined surfaces- sustainable machining: dry, near-dry, or Minimum Quantity Lubrication (MQL) and cryogenic machining processes precision and micro/nano machining- design and implementation of in-process sensors for monitoring and control of machining performance- surface integrity in machining processes, including detection and characterization of machining damage- new and advanced abrasive machining processes: design and performance analysis- cutting fluids and special coolants/lubricants- nontraditional and hybrid machining processes, including EDM, ECM, laser and plasma-assisted machining, waterjet and abrasive waterjet machining