Finite element analysis of horn profiles used in ultrasonic assisted electrical discharge machining machine Online publication date: Thu, 20-Apr-2023
by Ashok Yadav; Vinod Yadava
International Journal of Design Engineering (IJDE), Vol. 11, No. 2, 2022
Abstract: In electrical discharge machining, if the debris density becomes too big in inter-electrode gap, there is reduction in resistance, which encourages abnormal sparking, results in electrode damage, and slows down the material removal rate. To remove and flush debris from the cathode, the tool or work piece is made to vibrate with the help of an ultrasonic vibration mechanism, and dielectric has to be forced to flow. In this investigation, conical and exponential horn with tool was designed and made to vibrate at resonance frequency. During operation, very high acoustic, hydrostatic, and jet flushing pressures are acting on the tool which can damage the tool and horn. Stresses developed in the horn and tool will not be over the yield/endurance strength, with controlled input parameters. Thermal analysis of thw horn was done to identify the chances of the tool failing due to sparking and to differentiate these two horns as per analysis.
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