Abstract
Ultrasonic vibrations of electrode-tool and workpiece were applied successfully in specific cases to increase some parameters at micro-EDM, this working mode being characterized through machining instability due to vary narrow working gap. Our researches proved that all main technological parameters of micro-EDM can be improved by ultrasonic aiding (μEDM+US) in terms of machining rate, volumetric relative wear and surface roughness if some optimization conditions of working parameters are fulfilled. A multiphysics Finite Element Analysis (FEA) of material removal mechanism was achieved using two time dependent modules of Comsol 4.2 in order to attain the working parameters optimization. The FEA results compared to experimental data aiming at model validation led to some useful measures to optimize the working parameters. The knowledge management process was approached in order to suggest how human resource from an organization that uses μEDM+US can apply and improve the research results. Our EDM+US strategy is based on relative long pulse time with very low current overlapped on collective bubbles implosion occurring at the final of a liquid ultrasonic stretching semiperiod, and relative low consumed power on ultrasonic chain, contributing to increase the main output technological parameters mentioned above.
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