The Device Design And Experimental Study On Horizontal Ultrasonic EDM

EDM is a special processing method, which meets the technological requirements byusing the releasing energy between the tool electrodes and work piece. It usually works inliquid medium, like EDM fluid or kerosene. Due to the merit of working in complicated surfaceand high machining accuracy, it is widely used in abrasive manufacturing, aerospace,precision machinery, biological and medical fields.But EDM works slowly and has low machining efficiency, which can be made up byultrasonic machining technology. Presently, the combination machine of U-EDM installs theultrasonic device on the EDM main shaft, which will affect the machining accuracy of EDMalthough the effect is better. So we consider to put the ultrasonic device on the work piece tomake fully advantages of EDM and ultrasonic machining technology.In this paper, we design a set of ultrasonic device and carry on the theoretical researchand the parameter design about the amplitude transformer, especially the conical three-stepcomposite amplitude transformer. ANSYS simulation and harmony response analysis aremade on the whole processing device. The experimental results show that it can reach to theexpected vibration effect when the work piece has a maximum amplitude on the end face.Then, we find the optimal parameter set through the orthogonal experimental study on theordinary EDM, on the basis of which two parameters of ultrasonic frequency and ultrasonicpower are added to study the ultrasonic effect on the mechanism of electrical dischargemachining. This article mainly studies the surface quality of work piece and measure thesuperiority of the processing through surface roughness. The results show that the U-EDMforms small flat and smooth pit and has a better surface integrity than EDM. Also theroughness is reduced, Finally, through the work piece surface integrity, the thesis discusses the ultrasonic effecton the mechanism of EDM. The introduction of ultrasonic makes the maximum discharge gapgets bigger and the minimum discharge gap gets narrowed, so the scope of the machining gapgets larger. At the same time, it makes the transfer of the discharge point by avoiding theproduce of arc discharge. The eddy current and pump suction effect accelerate the flow of theworking liquid. It also improves the processing environment, eventually forming a bettermachining surface.