Ultrasonic Assisted Electrical Discharge Machining for High Aspect Ratio Blind Holes

In order to improve the performance of the Electrical Discharge Machining (EDM) process, variety of works have been done during the last decades. In this paper, Ultrasonic Vibration has been used to improve the machining time and workpiece accuracy. The presented case study is a horizontal blind hole with an external diameter of 1 mm and an aspect ratio of 14. The main difficulty found was the evacuation of the debris due to the high aspect ratio and the horizontal position of the hole, which affects the machining stability decreasing the material removal rate. For this machining process analysis copper rod tool electrode and 1.2379 tempered alloy steel workpiece have been used. The results show that by Ultrasonic Assisted EDM process a reduction of 58% in machining time can be achieved without affecting the workpiece accuracy.

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