Study on the effective discharge energy mechanism of vertical ultrasonic vibration assisted EDM processing

Compared to traditional EDM processing, UEDM (Ultrasonic Vibration Assisted EDM) have a great improvement in optimizing discharge environment. In this study, ultrasonic vibration is attached to the electrode. According to the relative positional relationship between the movement path of the electrode tip and the discharge gap, four working states of UEDM are defined. The four working states are the path within the discharge gap, the path in contact with the edge of the discharge gap, part of the electrode end path outside the discharge gap, and the path in contact with the workpiece, respectively. States are analyzed from the effective discharge energy and discharge frequency. A mathematical model for effective discharge energy and surface roughness is established for two conventional working states. The correctness of the theoretical research is verified by experiments. As the experiment results shown, the influence of ultrasonic amplitude on the energy of UEDM is primary, while frequency is secondary. A working state with better discharge stability and higher discharge energy when the electrode end path is in contact with the edge of the discharge gap. In the first three conventional machining states, the surface quality of the workpiece increases with the increase of ultrasonic amplitude and frequency. The study can provide scientific guidance for parameter matching of UEDM.