Effect of combined ultrasonic vibration and electric discharge grinding on surface quality and material removal efficiency

To investigate the effects of ultrasonic vibration-assisted electrical discharge grinding (UVEDG) on machining efficiency and surface quality, the influence of various parameters on material removal rate (MRR) and surface roughness was analyzed to reveal the advantages of this process. The experiments were conducted using a CNC electrical discharge machine equipped with an ultrasonic vibration workbench, and the effects of parameters such as current, amplitude, abrasive grit size, and rotational speed were analyzed. The results indicate that introducing ultrasonic vibration significantly improves the MRR achievement rate and reduces the difference between theoretical and actual MRR. Increasing the abrasive grit size reduces surface roughness by 62.7%, and lower grit sizes achieve higher MRR under specific conditions. Increasing current enhances MRR but requires balancing chip removal and energy distribution. UVEDG optimizes chip removal and energy distribution through ultrasonic cavitation effects, reducing surface roughness by an average of 48.97% compared to traditional EDM grinding, with the highest reduction reaching 57.59%.