Ultrasonic vibration electrical discharge machining in gas

A new method of ultrasonic vibration electrical discharge machining (UEDM) in gas is proposed in this paper. It is shown that electrical discharge machining (EDM) with ultrasonic aid can be achieved well in a gas medium. The tool electrode is formed into a thin-walled pipe, and a high pressure gas medium is supplied through it. During machining, ultrasonic vibration of the workpiece can improve the machining process. Molten workpiece material can be ejected from the base body of the workpiece with the aid of ultrasonic vibration and be removed/flushed out of the working gap without becoming reattached to the electrode. Selecting #45 steel and copper as the workpiece material and electrode material, respectively, experiments have been carried out, the results showing that UEDM is a method with a high material removal rate (MRR). The greatest advantages of this technique are lower pollution and a low electrode wear ratio. (C) 2002 Elsevier Science B.V. All rights reserved.