FEM Modeling of Ultrasonic Vibration Assisted work-piece in EDM Process

In Electrical Discharge Machining, oxides (or debris) are created and accumulated in the sparking gap between an electrode and a work piece. If the debris density becomes too great in certain points in the gap, there is a reduction in the resistance, which encourages the formation of abnormal discharges, results in significant electrode damage and slows down the material removal rate. To enhance the flushing of debris particles, ultrasonic vibration is provided to work piece. In this paper an attempt has been made to develop mathematical model for ultrasonic assisted Electric Discharge Machining (UEDM). The finite element analysis of flushing due to ultrasonic vibration assisted EDM is performed and results are compared with EDM. Results are compared in term of velocity contour of fluid in the x and y direction along with pressure distribution. Ultrasonic vibration is provided to work piece, which improves the dielectric flushing from working zone and reduce the arcing. Due to better flushing, more debris particles are carried away from the machining area for the increase in material removal rate. Keywords-Ultrasonic Assisted Electric Discharge Machining (UEDM), EDM, FEM, modeling, flushing.