A study on the Effect of ultrasonic vibrations on electrical discharge machining processes

Ultrasonic vibrations have various kinds of applications in machining operations. A large number of researchers havebeen involved in the investigation of ultrasonic effects in conventional machining operations. In most of the cases, theyhave obtained favorable effects. In this regard, this paper discusses the effects of ultrasonic vibrations, especially in EDMprocesses. The mechanisms which are helpful in improving the material removal include, cavitation, micro-streamingand impact forces by ultrasonic waves. One of the major challenges in EDM is to improve the sparking and flushingefficiency, which is critical in processes such as micro-EDM. Generally, it is understood that ultrasonic vibrations reducethermal damage of the surfaces generated in EDM. Two ultrasonic parameters influencing the processes are ultrasonicamplitude and frequency of ultrasonic vibration. Several researchers have done mathematical modeling of the effectsof ultrasonic vibrations in EDM. It helps in the prediction of key factors influencing the process, such as ultrasonic forcerequired for debris evacuation and debris concentration at the inter-electrode gap.