Modeling and experimental validation of material erosion process in axial ultrasonic vibration-assisted EDM

Modeling and experimental validation of material erosion process in axial ultrasonic vibration-assisted EDM | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Modeling and experimental validation of material erosion process in axial ultrasonic vibration-assisted EDM Yan Wang, Wenyu Wang, Wenhui Li, Guijiu Xie, Tianyi Sui, Yinghuai Dong, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7205750/v1 This work is licensed under a CC BY 4.0 License Status: Under Revision Version 1 posted 5 You are reading this latest preprint version Abstract Ultrasonic vibration-assisted EDM has attracted significant attention due to its ability to obtain better machining quality. In this paper, the inter-electrode energy distribution relationship of axial ultrasonic vibration assisted EDM (Ax-UEDM) was analyzed. Combined with heat transfer, a vibro-electro-thermal model was developed for describing the material erosion process. The model reveals and presents a dynamic correlation between ultrasonic energy, electrical energy, thermal energy and surface topography. By controlling the ultrasonic energy or adjusting the parameters, the surface topography can be simulated and tuned. As the ultrasonic vibration amplitude increases from 5µm to 15µm, the energy acting on the cathode decreases by 2.4–20.8% compared to EDM. According to the experimental results, it resulted in a reduction of surface crater radius by 6.25-30%. When the ultrasonic vibration amplitude is 15 µm, the surface roughness is reduced by 20.8%. This study reveals the mechanism of matching and transforming multiple energy fields (ultrasonic energy, electrical energy, and thermal energy), and realizes the micro-regulation of composite energy fields. Provides the necessary theoretical basis for process improvement in Ax-UEDM. Energy distribution Axial ultrasonic vibration UEDM Material erosion process Full Text Cite Share Download PDF Status: Under Revision Version 1 posted Editorial decision: Major Revisions Needed 18 Mar, 2026 Reviewers agreed at journal 12 Nov, 2025 Reviewers invited by journal 07 Sep, 2025 Editor assigned by journal 27 Jul, 2025 First submitted to journal 24 Jul, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7205750","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":511356692,"identity":"be52d813-f733-4aee-b1d9-30ee85adfcb5","order_by":0,"name":"Yan Wang","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Yan","middleName":"","lastName":"Wang","suffix":""},{"id":511356693,"identity":"bbbe4e0f-cfce-4e2a-9293-91e9afdfdcc9","order_by":1,"name":"Wenyu 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Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Energy distribution, Axial ultrasonic vibration, UEDM, Material erosion process","lastPublishedDoi":"10.21203/rs.3.rs-7205750/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7205750/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eUltrasonic vibration-assisted EDM has attracted significant attention due to its ability to obtain better machining quality. In this paper, the inter-electrode energy distribution relationship of axial ultrasonic vibration assisted EDM (Ax-UEDM) was analyzed. Combined with heat transfer, a vibro-electro-thermal model was developed for describing the material erosion process. The model reveals and presents a dynamic correlation between ultrasonic energy, electrical energy, thermal energy and surface topography. By controlling the ultrasonic energy or adjusting the parameters, the surface topography can be simulated and tuned. As the ultrasonic vibration amplitude increases from 5\u0026micro;m to 15\u0026micro;m, the energy acting on the cathode decreases by 2.4\u0026ndash;20.8% compared to EDM. According to the experimental results, it resulted in a reduction of surface crater radius by 6.25-30%. When the ultrasonic vibration amplitude is 15 \u0026micro;m, the surface roughness is reduced by 20.8%. This study reveals the mechanism of matching and transforming multiple energy fields (ultrasonic energy, electrical energy, and thermal energy), and realizes the micro-regulation of composite energy fields. 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