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The cycle of relative motion (up and down) of the tool continues until the required shape or geometry is attained. The process stability, productivity and part quality are directly influenced by the ultrasonic vibration amplitude and frequency, tool material and dielectric type. 4 Applications Important applications of USEDM are: machining of hard and brittle materials such as carbides and ceramics, high aspect ratio holes and deep cavities, fabrication of micro-parts and electrodes for EDM itself.

The abrasive particles are accelerated by the vibro-impact motion of the tool electrode that is driven by the ultrasonic transducer. The passivating layer is then removed by these ultrasonically accelerated abrasives that impact the workpiece surface. This process also helps to maintain a constant inter-electrode gap. The cycle continues until the required work geometry or shape is formed. 3 Process Mechanism and Parameters The success of ECM depends on material removal from the anode (workpiece) surface by electrochemical dissolution.

2 Equipment and Working Principle A typical USECM system along with its various components is shown in Fig. 2. It includes an ECM system consisting of a DC power supply, tool electrode and its feed mechanism; components of ultrasonic system viz. ultrasonic transducer (preferably piezoelectric) coupled with ultrasonic generator, horn with a tool holder to transmit the ultrasonic energy to the tool and for amplifying the tool stroke, and an electrolyte containing an appropriate abrasives. Usually, a DC voltage of between 2 and 30 V is applied across the anodic workpiece and cathodic tool for material removal by electrochemical action in this process.

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CAS-CERN Accelerator School - Applied Geodesy for Particle Accelerators


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