Theoretical and experimental study on localization improvement in ultrasonic vibration-assisted spark-assisted electrochemical drilling process

Spark-assisted electrochemical machining (SAEM) is an advanced machining method, which can manufacture microstructures on non-conductive hard and brittle materials such as glass. However, there are still some technological problems in the process of SAEM, among which the poor machining localization and the damage of microhole outlet are still unresolved. In order to improve the localization and quality of machining, a method of ultrasonic vibration-assisted spark-assisted electrochemical drilling (UASAED) was proposed in this paper. The application of ultrasonic vibration can reduce the gas film thickness and improve its stability in the spark-assisted electrochemical machining process, and reduce the discharge energy, so the machining localization and quality can be improved. Firstly, the formation of gas film in the drilling process was simulated and the influence of ultrasonic vibration on the gas film was analyzed. Secondly, the mechanism of material removal during drilling process was studied and simulated, and the mathematical model was established. Then, through a series of experiments, according to the established mathematical model, the relationships between the key machining parameters and the machining localization were studied, and the experimental results were consistent with the simulation. Finally, according to the machining parameters optimized by single factor experiments, 4 x 5 high-quality glass microhole array was successfully machined. The diameters of microholes were significantly reduced, with the inlet diameter decreasing by 20.59% and the outlet diameter by 14.9%, which indicated that ultrasonic vibration-assisted spark-assisted electrochemical drilling is an effective method to improve the machining localization.

Automated summary

This paper proposes a method of ultrasonic vibration-assisted spark-assisted electrochemical drilling (UASAED) to solve the problems of poor machining localization and damage of microhole outlet in spark-assisted electrochemical machining (SAEM). Through simulation and experimental research, the machining parameters were optimized and high-quality glass microholes were successfully machined.