Title: Finite element analysis of horn profiles used in ultrasonic assisted electrical discharge machining machine

Authors: Ashok Yadav; Vinod Yadava

Addresses: Department of Mechanical Engineering, Motilal Nehru National Institute of Technology, Allahabad, Prayagraj, Uttar Pradesh, 211004, India ' Department of Mechanical Engineering, Motilal Nehru National Institute of Technology, Allahabad, Prayagraj, Uttar Pradesh, 211004, India

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.

Keywords: ultrasonic assisted EDM; horn stresses; thermal analysis; finite element analysis; acoustic and vibration.

DOI: 10.1504/IJDE.2022.130437

International Journal of Design Engineering, 2022 Vol.11 No.2, pp.119 - 150

Accepted: 29 Sep 2022
Published online: 20 Apr 2023 *

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