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A study on ultrasonic-assisted micro-EDM of titanium alloy

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Abstract

Titanium alloy is widely used in high-precision fields such as aerospace industries and medical equipment because of its corrosion resistance and heat resistance. In conventional micro-EDM, the machining of small deep holes of difficult-to-cut materials has always been a problem due to difficult waste debris discharge and low machining efficiency when the machined aperture is small and the aspect ratio is large. Based on the above shortcomings, the high-frequency ultrasonic vibration was introduced into micro-EDM to improve processability. And the optimal ultrasonic system was designed on analytical calculation, finite element simulation, impedance test, and error analysis. The system was applied to SE-WK008 microporous machine for titanium alloy drilling test, and the univariate control experiment based on ultrasonic parameters and electrical parameters (processing voltage, pulse width, pulse interval, and peak current) was carried out. The influence law of each parameter on processing efficiency and electrode wear was summarized and the experimental data was fitted with polynomial curves, and then the multi-objective particle swarm optimization (MOPSO) algorithm was used to find out the optimal parameter array to verify the correctness of the selected processing parameter group. Through experimental analysis, the designed ultrasonic system can be applied to the traditional microporous machine, the highest processing efficiency is increased by 82.7%, and the maximum electrode wear is reduced by 68.7%, which points out the direction for the parameter selection of actual small deep hole machining.

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Availability of data and material

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

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Funding

This work is supported by the National Natural Science Foundation of China (Grant No. [51875532]); Achievement Transformation and Cultivation Project of Shanxi Province in 2021 (Grant No. [2021047]); and Graduate Innovation Project of Shanxi Province in 2021 (Grant No. [2021Y586]).

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Authors and Affiliations

  1. School of Mechanical Engineering, North University of China, Taiyuan, 030051, Shanxi, China

    Wang Pengxiang, Yu Daguo & Li Menglong

  2. Shanxi Deep Hole Processing Engineering Technology Research Center, Taiyuan, 030051, Shanxi, China

    Wang Pengxiang, Yu Daguo & Li Menglong

Authors
  1. Wang Pengxiang
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  2. Yu Daguo
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  3. Li Menglong
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Contributions

All the authors have contributed to the research conception and design. Material preparation, data collection and analysis were carried out by Wang Pengxiang, Yu Daguo, and Li Menglong. The first draft of the manuscript was written by Wang Pengxiang, and all authors commented on the previous version of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Wang Pengxiang.

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Wang, P., Yu, D. & Li, M. A study on ultrasonic-assisted micro-EDM of titanium alloy. Int J Adv Manuf Technol 121, 2815–2829 (2022). https://doi.org/10.1007/s00170-022-09355-1

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