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<p>Ultrasonic vibration-assisted powder-mixed electrical discharge machining (UV-PMEDM) was employed to improve processing efficiency and quality in the machining of TiN ceramics. The process parameters of UV-PMEDM were optimized using quadratic regression models developed through response surface methodology. The goal was to maximize the material removal rate (MRR) while minimizing surface roughness (SR). Analysis of variance, error analysis, and response surface analysis were conducted to evaluate the impact of parameters on performance. The regression models demonstrated high accuracy and reliability. The optimal parameters included an ultrasonic amplitude of 8&#xa0;μm, a powder-mixed concentration of 1.5&#xa0;g/L, a pulse-on time of 320&#xa0;μs, and a pulse-off time of 240&#xa0;μs. Verification experiments using these settings resulted in an MRR improvement of 39%, reaching 0.516&#xa0;mm<sup>3</sup>/min, and a 23% reduction in SR to 2.342&#xa0;μm. Moreover, the optical profiler micrograph analysis indicated that UV-PMEDM produced fewer microcracks than conventional EDM, ultrasonic vibration-assisted EDM, and powder-mixed EDM. This optimization effectively enhanced processing efficiency and surface quality in TiN ceramics.</p>

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Optimization of Process Parameters in Ultrasonic Vibration-Assisted Powder-Mixed Electrical Discharge Machining of TiN Ceramics

  • 期刊论文

  • 发表日期：

    2025年2月19日

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  • Jianqing Han,
  • Xiang Gao,
  • Yongqiang Zhou,
  • Zhen Li,
  • Minghao Gao,
  • Yongbing Hao,
  • Qinhe Zhang

摘要

Ultrasonic vibration-assisted powder-mixed electrical discharge machining (UV-PMEDM) was employed to improve processing efficiency and quality in the machining of TiN ceramics. The process parameters of UV-PMEDM were optimized using quadratic regression models developed through response surface methodology. The goal was to maximize the material removal rate (MRR) while minimizing surface roughness (SR). Analysis of variance, error analysis, and response surface analysis were conducted to evaluate the impact of parameters on performance. The regression models demonstrated high accuracy and reliability. The optimal parameters included an ultrasonic amplitude of 8 μm, a powder-mixed concentration of 1.5 g/L, a pulse-on time of 320 μs, and a pulse-off time of 240 μs. Verification experiments using these settings resulted in an MRR improvement of 39%, reaching 0.516 mm3/min, and a 23% reduction in SR to 2.342 μm. Moreover, the optical profiler micrograph analysis indicated that UV-PMEDM produced fewer microcracks than conventional EDM, ultrasonic vibration-assisted EDM, and powder-mixed EDM. This optimization effectively enhanced processing efficiency and surface quality in TiN ceramics.