Sabyrov Nurbol, Jahan M P, Bilal Azat, Perveen Asma
Department of Mechanical & Aerospace Engineering, Nazarbayev University, Astana 010000, Kazakhstan.
Department of Mechanical Engineering, Miami University, Oxford, OH 45056, USA.
Materials (Basel). 2019 Feb 10;12(3):522. doi: 10.3390/ma12030522.
Many of the industrial processes, including material removal operation for shape generation on the surface of material, exploit the assistance of ultrasonic vibrations. This trend of using ultrasonic vibration in order to improve the process performance is becoming more and more prominent recently. One of the significant applications of this ultrasonic vibration is in the industrial processes such as Electro-discharge machining (EDM), where ultrasonic vibration (UV) is inserted as a medium for enhancing the process performance. Mostly ultrasonic vibration is applied along with the EDM process to increase the efficiency of the process through debris cleansing from the sparking gap. There have been significant changes in ultrasonic assisted technology during the past years. Due to its inherent advantages, ultrasonic assistance infiltrated in different areas of EDM, such as wire cut EDM, micro EDM and die sinking EDM. This article presents an overview of ultrasonic vibration applications in electric discharge machining. This review provides information about modes of UV application, impacts on parameters of performance, optimization and process designing on difficult-to-cut materials. On the bases of available research works on ultrasonic vibration assisted EDM, current challenges and future research direction to improve the process capabilities are identified. Literature suggested improved material removal rate (MRR), increased surface roughness (SR) and tool wear ratio (TWR) due to the application of ultrasonic vibration assisted EDM. However, tool wear and surface roughness can be lessened with the addition of carbon nanofiber along with ultrasonic vibration. Moreover, the application of ultrasonic vibration to both tool and workpiece results in higher MRR compared to its application to single electrode.
许多工业加工过程，包括在材料表面进行形状生成的材料去除操作，都借助了超声振动的辅助。近来，利用超声振动来提高加工性能的这一趋势愈发显著。这种超声振动的一个重要应用在于诸如电火花加工（EDM）等工业加工过程中，其中超声振动（UV）被引入作为提高加工性能的一种手段。大多数情况下，超声振动与电火花加工过程一起应用，通过清除放电间隙中的碎屑来提高加工效率。在过去几年里，超声辅助技术发生了重大变化。由于其固有优势，超声辅助已渗透到电火花加工的不同领域，如线切割电火花加工、微电火花加工和型腔电火花加工。本文概述了超声振动在电火花加工中的应用。这篇综述提供了关于超声振动应用模式、对性能参数的影响、对难切削材料的优化及工艺设计等方面的信息。基于关于超声振动辅助电火花加工的现有研究工作，确定了当前提高加工能力面临的挑战和未来的研究方向。文献表明，由于应用超声振动辅助电火花加工，材料去除率（MRR）提高，表面粗糙度（SR）和工具磨损率（TWR）增加。然而，在超声振动的同时添加碳纳米纤维可以减少工具磨损和表面粗糙度。此外，与仅将超声振动应用于单个电极相比，将超声振动同时应用于工具和工件可获得更高的材料去除率。
