Ultrasonic Vibration Assisted Micro Electrochemical Discharge Drilling Technology*

Electrochemical Discharge Machining (ECDM) is an effective way to fabricate micro holes, channels and kerfs on non- conductive materials. In this paper, material removal mechanism of ECDM was discussed and model for gas film formation was established. Meanwhile, a series of experiments for micro drilling were carried out to demonstrate the advantages of Ultrasonic Vibration Assisted Electrochemical Discharge Machining (UAECDM). Results have shown that the machining voltage is significantly reduced while ultrasonic vibration is applied to the tool electrode, and both accuracy and stability of the machining process are improved consequently. Finally, 3 *3 array holes were fabricated with small thermal crack area around the inlet and no breakage at the outlet.