Abstract
Ultrasonic vibration (USV) and magnetic field (MF) complex assisted techniques are combined with low speed wire electrical discharge machining (USV-MF complex assisted WEDM-LS) to improve the machining performance of conventional WEDM-LS. Firstly, the simulation results of multi-physical coupling simulation model show that under the influence of ultrasonic vibration, the working fluid fluidity is greatly enhanced and its temperature is significantly decreased. Then, a three-phase flow model of bubble, working fluid and debris in the machining area is established to investigate the effects of ultrasonic vibration on bubble and debris, and the process of bubble rupture is simulated. The simulation results show that with the increase of ultrasonic frequency, the movement of bubble and debris becomes fiercer and fiercer, when ultrasonic frequency is 30 kHz and ultrasonic amplitude is 10 μm, the bubble is collapsed. Finally, comparison of the experimental results of conventional WEDM-LS, USV assisted WEDM-LS, MF assisted WEDM-LS and USV-MF complex assisted WEDM-LS in machining TiNi-01 shape memory alloy reveals that the ratio of normal discharge and the material removal rate are both increased, the workpiece surface roughness value is decreased and the workpiece surface quality is improved in the process of USV-MF complex assisted WEDM-LS.
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