Initial Research on Ultrasonic Vibration-Assisted EDM for Processing Cylindrical Surfaces

Electrical discharge machining represents a non-conventional machining process, specifically designed for the effective fabrication of materials that are difficult to machine and for components with complex geometries. Many studies have been carried out that combine electrical discharge machining with the ultrasonic vibration of electrodes. Nevertheless, most of these investigations have concentrated on the processing of hole or cavity components. This document presents an experimental study focused on the design of an electrode holder for ultrasonic vibration electrical discharge machining, focusing on the machining of cylindrical surfaces. This study involved a two-stage design process for the electrode holder, aimed at determining the optimal length to achieve the maximal material removal rate and to ensure surface roughness. The novel aspect of this study is that it is the first to be published on the use of ultrasonic vibration in the electrical discharge machining process for processing cylindrical surfaces. Furthermore, splitting the electrode holder design process into two stages (theoretical calculation and experimental determination) made it possible to identify an electrode holder design for ultrasonic vibration electrical discharge machining that increased the MRR by 35.5% while maintaining SR values that were similar to those produced during the electrical discharge machining without ultrasonic vibration.