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<p>The small discharge energy and narrow discharge gap inherent in deep micro-hole drilling by micro electrical discharge machining (MEDM) can lead to difficulties in removing electro-erosion debris. In this study, ultrasonic vibration and a magnetic field were incorporated into a conventional micro electrical discharge machining (CMEDM) machine to create a novel hybrid machining process based on MEDM. The combined effects of ultrasonic vibration and the magnetic field on MEDM were investigated to achieve high-efficiency and high-quality drilling of deep micro-holes. The process parameters for drilling deep micro-holes in titanium alloy were optimized using response surface methodology (RSM), with the material removal rate (MRR) as the optimization objective. The results indicated that the optimal combination of process parameters to maximize the MRR included an ultrasonic amplitude of 4.2&#xa0;μm, a magnetic induction intensity of 155 mT and a peak current of 54.6 A. Additionally, the composition and mechanical properties of the changed layer, including surface morphologies, element composition, microhardness, and residual stress, were analyzed in this paper.</p>

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Study on deep micro hole machining characteristics of magnetic field assisted micro electrical discharge machining with ultrasonic vibration of workpiece

  • 期刊论文

  • 发表日期：

    2025年6月16日

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  • Peng Yu,
  • Sijun Dong,
  • Yongcheng Gao,
  • Xiaodong Zhang,
  • Zhongxu Lian,
  • Yiquan Li,
  • Jinkai Xu,
  • Hailong Cui,
  • Huadong Yu

摘要

The small discharge energy and narrow discharge gap inherent in deep micro-hole drilling by micro electrical discharge machining (MEDM) can lead to difficulties in removing electro-erosion debris. In this study, ultrasonic vibration and a magnetic field were incorporated into a conventional micro electrical discharge machining (CMEDM) machine to create a novel hybrid machining process based on MEDM. The combined effects of ultrasonic vibration and the magnetic field on MEDM were investigated to achieve high-efficiency and high-quality drilling of deep micro-holes. The process parameters for drilling deep micro-holes in titanium alloy were optimized using response surface methodology (RSM), with the material removal rate (MRR) as the optimization objective. The results indicated that the optimal combination of process parameters to maximize the MRR included an ultrasonic amplitude of 4.2 μm, a magnetic induction intensity of 155 mT and a peak current of 54.6 A. Additionally, the composition and mechanical properties of the changed layer, including surface morphologies, element composition, microhardness, and residual stress, were analyzed in this paper.