| dc.description.abstract | This study employs Electrochemical Discharge Machining (ECDM) combined
with ultrasonic vibration assistance, using a stepped, flat tungsten carbide tool
electrode to machine through-slots in 0.3 mm thick quartz glass. The research
investigates the effects of various machining parameters on machining quality,
including working voltage, concentration of surfactant, ultrasonic output power
level, and feed rate.
In the first stage, the UA-ECDM, equipped with a self-made load cell feedback
control system, automatically adjusts the feed rate during machining to prevent
cracks caused by the material removal rate of the workpiece being slower than the
feed rate of the tool electrode. After machining the through-slot with UA-ECDM,
the second stage involves UVAG machining using the same setup to avoid tool
change and maintain positioning accuracy. This stage continues the feed on a
precision moving platform, introducing diamond abrasive slurry, and employs
high-frequency ultrasonic vibration to continuously grind the workpiece.
Ultrasonic grinding is used to deburr the through-slot edges formed in the first
stage of electrochemical discharge, completing the second stage of machining.
Finally, the study observes the inlet and outlet dimensions, the amount of outlet
burrs, and the electrical discharge consumption after machining.
The use of ultrasonic vibration-assisted micro-groove machining utilizes highfrequency ultrasonic vibrations to cause pressure changes in the electrolyte, which
creates a pumping effect and disturbs the electrolyte. This disturbance accelerates
the removal of reaction heat and various machining by-products from the
machining area, thereby improving the efficiency of electrolyte circulation as the
IV
machining depth increases. Additionally, adding surfactants enhances the
wettability of the tool electrode surface, contributing to improved machining
efficiency. Experimental results show that surfactants help increase machining
depth, and ultrasonic vibration assistance can reduce the affected area of etching.
By combining the advantages of both auxiliary media, it is possible to machine
through-grooves and improve the fragmentation at the groove exit by adjusting
the feed rate. Finally, ultrasonic grinding achieved micro-groove dimensions of
0.459mm * 3.063mm at the inlet and 0.446mm * 3.064mm at the outlet, with an
electrode wear rate of 0.776%. | en_US |