Flow field simulation of ultrasonic vibration assisted EDM of holes array

Debris distribution in the bottom and side gap significantly affects machining performance of electrical discharge machining (EDM) of holes array. Therefore, the mechanisms of debris distribution and velocity field of flow field in the discharge gap between tool electrode and workpiece should be investigated. In this paper, a two-dimensional model of flow field for ultrasonic assisted EDM of holes array was created by computational fluid dynamics. The evolution of debris distribution process and velocity field of flow field during an ultrasonic vibration cycle was discussed through the numerical simulation. The results show that holes in the center of the array are larger than those at the periphery, which is caused by debris distribution and concentration. Machining experiments were conducted to verify the simulation results of debris distribution during EDM of holes array.