Dimensional accuracy enhancement of machined-hole through UAECDM-process under the magnetic-field-assistance

Abstract

ABSTRACT Electrochemical discharge machining (ECDM) is a micro-machining hybrid technique that utilizes electrical discharge and electrochemical machining principles. However, the issue of insufficient electrolyte in the hydrodynamic region hinders the continuation of the machining action. Although ultrasonic tool vibrations have been used to overcome this problem to some extent, the excessive mechanical energy produced by high-amplitude tool vibration may lead to surface crack formations. As a result, the present work employs two flushing improvement methods, namely the ultrasonic vibrations and magnetic filed assistances, in the ECDM process. A comparative study has been performed to identify the effect of the magnetic field on discharge quality. The material removal rate and depth of penetration were increased by 11% and 24%, respectively, and the observed reduction in hole overcut and taper angle was around 35% and 50%, respectively. Optical microscope images quantified improvement in dimensional accuracy and decreased HAZ area.