Multi-objective parameter optimization of ultrasonic vibration–assisted micro-EDM of Ti-6Al-4V alloys
Jinkai Xu, Shijie Xia, Peng Yu, Mingyu Li
Abstract
Regarding the low machining efficiency and poor surface quality in micro-electrical discharge machining (μ-EDM) of large depth-to-diameter ratio micro-holes, this paper focuses on ultrasonic vibration–assisted multi-objective optimization in μ-EDM to achieve high material removal rate (MRR) and low tool wear rate (TWR). In this work, second-order quadratic models were developed for MRR and TWR, considering the peak voltage ( U p ), peak current ( I p ), pulse width ( Width), frequency ( Freq.), ultrasonic amplitude ( UA), and rotation speed ( Rot.) as the machining parameters, using the Plackett–Burman design and Box–Behnken design. The developed models were used for multi-objective optimization by desirability function approach to determine the optimum machining parameters. The optimized parameters were processed for micro-holes, and it was found that the surface quality of the micro-holes was significantly improved.