Numerical and Experimental Investigation of Magnetic Field and Ultrasonic Vibrations Assisted EDM Process

In this investigation, finite element method was used to model single discharge of ultrasonic vibrations and magnetic field assisted electrical discharge machining (MUEDM) process. Regarding good correlation between theoretical recast layer thickness obtained by process modeling and experimental recast layer thickness obtained by experiments with maximum error of 8.6%, the developed numerical model was used to find the temperature distribution at workpiece surface and predict the created craters dimensions on workpiece surface. The influences of applying ultrasonic vibrations to tool electrode simultaneous with applying external magnetic field around gap distance of electrical discharge machining (EDM) process, on plasma flushing efficiency, recast layer thickness and created craters dimensions were found by numerical and experimental analysis. The experimental and numerical results showed that applying magnetic field around gap distance and ultrasonic vibrations to tool electrode, simultaneously, at EDM process increases plasma flushing efficiency and decreases recast layer thickness. Also, applying magnetic field around gap distance and ultrasonic vibrations to tool electrode, simultaneously, at EDM process, leads to higher depth and volume of created craters on machined surface and lower craters radius.