An analysis of the debris in ultrasonic-assisted electrical discharge machining

• Published in: Wear Vol. 117; no. 2; pp. 241 - 250
• Main Authors: Murti, V.S.R., Philip, P.K.
• Format: Journal Article
• Language: English
• Published: Lausanne Elsevier B.V 15.06.1987; Amsterdam Elsevier Science; New York, NY
• Subjects: Applied sciences; Cross-disciplinary physics: materials science; rheology; Cutting; Exact sciences and technology; Materials science; Metals, semimetals and alloys; Metals. Metallurgy; Other machining methods; Physics; Production techniques; Specific materials; Sphere; Scanning electron microscopy; Particle size; Shape; Ultrasonic machining; Granularity; Grain size distribution; Dendritic structure
• ISSN: 0043-1648; 1873-2577
• DOI: 10.1016/0043-1648(87)90258-4

This paper endeavours to examine the influence of ultrasonic irradiation of the spark gap on electrical discharge machining debris. An analysis using scanning electron microscopy shows that most of the particles are globular in shape with slight ellipticity. Except for a few isolated hollow particles, the rest are solid. There is evidence of the collisions of particles in the form of splats, attached satellites, cracks and dents, etc. Compositional analysis showed pickup of tool electrode material by the debris. The size distribution was near normal, indicating the stochastic nature of particle formation. The pulse characteristics significantly influence the particle size. The influence of ultrasonics was highly significant with markedly high spheroidicity, size, copper pickup and incidence of collisions.