Study on an Ultrasonic Combined Electro-Machining Control System with Composite Material Experiments

Materials such as stainless steel, cemented carbide, metal matrix composites, etc., usually require combinations of multiple machining, due to their high hardness, high wear resistance, and other mechanical properties. Ultrasonic combined electro-machining (UCEM) is the preferred solution for the efficient machining of high hardness and high toughness products. However, the machining can deviate from the expected values for factors such as physical and chemical complexity and variability, as well as tool head wear, which can make it difficult to keep the process stable, thus leading to a decrease in machining efficiency. To address the above problems, this study constructed and optimized a UCEM detection and control system based on an analysis of the mutual coordination mechanism of each effects of combined machining, and proposed a machining short-circuit avoidance method based on inter-pulse voltage detection that can avoid the irreversible harm caused by the high current generated during electrode short-circuiting in electrolytic machining. This method could be of great value and significance in preventing workpiece burns and improving machining quality.