Research On Ultrasonic Vibration EDM Compound Machining Of Tiny Holes And Fluid Simulation

The advantages of ultrasonic vibration EDM composite machining technology can effectively promote the perfect combination of the advantages of ultrasonic vibration and apply it to EDM,the advantages of ultrasonic-assisted vibration will effectively promote the movement in the gap flow field during the EDM process,and the high-speed movement of the gap flow field will improve the efficiency of the discharge of electrolytic corrosion products.This paper designs a two-section composite ultrasonic horn,and further explores the effect on the flow field of the EDM composite machining gap under different ultrasonic vibrations.Based on design requirements,a two-section composite ultrasonic horn was designed to obtain a larger magnification factor.The push section uses a stepped ultrasonic horn with a smaller form factor and a larger magnification factor,and the output section uses a stepped ultrasonic horn with a larger form factor.Use ANSYS software for modal analysis and harmonious response analysis to study the modal shape and amplification factor that meet the requirements.Fluent software was used to simulate the flow field of the EDM gap under different ultrasonic amplitudes.The simulation amplitudes were designed to be 10?m,20?m,30?m and 40?m,and the vibration frequency was f=20000Hz.Through mathematical model calculation,the average inlet velocity of the fluid model of the gap flow field in the four cases is obtained,and the average inlet velocity is used to simulate the fluid model to compare the maximum fluid pressure,maximum velocity and maximum turbulence value under different conditions.From the simulation data,it can be concluded that in ultrasonic EDM machining,increasing the ultrasonic vibration can help accelerate the movement of the gap flow field.When the ultrasonic amplitude increases,the increase rate of the maximum pressure,velocity and turbulence value is higher.This will improve the erosion of the electro-corrosion product by the working fluid between the electrodes,promote the discharge of the electro-corrosion product,improve the processing state,and increase the processing efficiency.