Ultrasonic Assisted EDM Deep Small Hole Machining Technology Based On Horizontal Vibration Of Workpiece

With the continuous development of science and technology,industrial production requires more and more precise parts processing,precision processing has become a trend.At present,the emergence of micro-parts such as automotive fuel injectors,micro-runners and Micro-fluids indicates that the processing accuracy of micro-deep holes in industrial production is transiting from micron to submicron.In this trend,the traditional processing methods have been difficult to meet the market demand for micro-hole parts.Therefore,combining the characteristics of EDM and Ultrasound-assisted Machining,a new horizontal Ultrasound-assisted EDM system for deep and small holes is designed and applied in physical machining.The details are as follows:1.The relationship and difference between horizontal ultrasonic vibration of workpiece and EDM are preliminarily discussed.By comparing the vertical ultrasonic vibration of electrodes,it is known that horizontal ultrasonic vibration of workpiece can not only retain the advantages of vertical ultrasonic vibration,but also not affect the feed accuracy and speed of spindle.2.Based on the structural characteristics of conical and stepped horns,a new type of horn is designed and its analytical formula is deduced.According to the calculation results,the dynamic analysis and simulation optimization of the horn are carried out to ensure that the structural parameters of the new horn meet the requirements of horizontal ultrasonic assisted EDM.3.Assemble the horizontal ultrasonic vibration system and measure its vibration characteristic curve and bearing capacity.At the same time,the experiment of horizontal ultrasonic vibration assisted EDM is carried out by combining the ultrasonic vibration system with the EDM machine tool.The experimental results show that the horizontal ultrasonic vibration of workpiece can promote the efficiency and depth of EDM,and improve the electrode wear and the inner surface roughness of small holes.By comparing the processing effects of different materials,it is found that the processing efficiency and depth of pig iron are better than those of stainless steel.In conclusion,the horizontal ultrasonic vibration system established in this paper not only improves the processing effect of conventional EDM to a certain extent,but also does not affect the spindle feed and working fluid circulation of EDM machine tools.It enriches the research direction of ultrasonic assisted EDM and has broad market prospects.