Review Article

Proc IMechE Part B:

J Engineering Manufacture
1–12
Ultrasonic vibration–assisted electric Ó IMechE 2015
Reprints and permissions:
discharge machining: A research sagepub.co.uk/journalsPermissions.nav
DOI: 10.1177/0954405415573061

review pib.sagepub.com

Bharat C Khatri1,2, Pravin Rathod3 and Janak B Valaki1,4

Abstract
Ultrasound waves are directly being used in many of the industrial applications including material removal for generating pro-
files on material surfaces. Trend has been shifted to use ultrasonic sound waves or ultrasonic vibrations as assisting media to
enhance process performance. Electric discharge machining is one such industrial application for material removal, where
ultrasonic vibrations have been introduced as assisting media for improving process performance. Ultrasonic vibrations were
mainly employed in electric discharge machining process for improved debris evacuation from the sparking gap to increase
process efficiency. It also resulted in stable and consistent sparking sequences by minimizing adverse arcing phenomenon in
electric discharge machining. Since its introduction, technology of ultrasonic assistance in electric discharge machining has
gone through considerable changes and penetrated to various variants of the electric discharge machining process mainly die
sinking electric discharge machining, wire cut electric discharge machining and micro electric discharge machining.
This article presents a research review for applications of ultrasonic vibrations for electric discharge machining pro-
cess. The review has been carried out in terms of modes of applying ultrasonic vibrations, effect on performance para-
meters, process modelling and optimization and application for difficult-to-cut advanced materials. Based on the review
of present status of the ultrasonic-assisted electric discharge machining, future research needs have been identified to
strengthen the capacity and capabilities of the electric discharge machining process.

Keywords
Ultrasonic vibration, electric discharge machining, ultrasonic vibration–assisted electric discharge machining, die sinking
electric discharge machining, wire cut electric discharge machining and micro electric discharge machining

Date received: 10 June 2014; accepted: 5 January 2015

Introduction results in significant tool wear and slows down the

material removal rate (MRR).3 Hence, in order to
Electric discharge machining (EDM) is a thermo-elec- maintain efficiency and consistency of the process,
tric-based non-conventional metal removal process effective evacuation of debris from the sparking gap
used to generate a wide variety of complex, intricate, plays an imperative role in EDM process.
slender, geometrically and dimensionally accurate pro-
files and features on punches and dies for plastic and
metal forming processes. EDM is a preferable process
for the manufacture of parts for aerospace, automotive 1
School of Engineering, RK University, Rajkot, India
2
industry, surgical and other medical implant applica- Mechanical Engineering Department, L. D. Engineering College,
tions.1,2 Material removal is accomplished by applying 3
Ahmedabad, India
Mechanical Engineering Department, Government Engineering College,
high-frequency pulsed discharge current to the work- Bhuj, India
piece through a dielectrically separated tool electrode. 4
Mechanical Engineering Department, Government Engineering College,
Dielectric fluid breaks down to cause melting and Bhavnagar, India
vaporization of the workpiece material. The material
removed in the form of debris is accumulated in the Corresponding author:
Bharat C Khatri, Mechanical Engineering Department, L.D. College of
machining gap and leading to reduction of resistance in Engineering, Opp. Gujarat University, Navarangpura, Ahmedabad 380015,
the gap, hence encourages the formation of abnormal India.
discharges through short circuits, which eventually Email: khatribharat752@yahoo.com

Downloaded from pib.sagepub.com by guest on May 6, 2015

2 Proc IMechE Part B: J Engineering Manufacture
Figure 1. (a) Ultrasonic-aided micro EDM7 and (b) ultrasonic-aided micro WEDM.8
Development of effective debris evacuation or flush-
ing methods to remove debris from sparking gap has
been the focus area of research in EDM since last
decade. Application of ultrasonic vibration is one of the
methods for debris evacuation in EDM. Ultrasonic
vibration–assisted electric discharge machining
(UVAEDM) is hybrid machining process, wherein
small-amplitude vibrations of specific frequency are
applied to either of the electrodes (tool/wire and work-
piece) or dielectric fluid to improve flushing and hence
machining efficiency.4 The basic principle of this pro-
cess clarifies that the ultrasonically vibrating electrode
or workpiece changes the sparking gap rapidly and gen-
erates a high-frequency alternating pressure variation in
the sparking gap. Constantly changing pressure assists
in better ejection of the molten materials. In addition,
the ultrasonic vibration improves dielectric circulation,
which in turn prevents the conglomeration of the debris
particles in the working gap. It facilitates effective deb-
ris removal and hence improves the discharge efficiency
and results in high MRR substantially.5
This article provides a detailed research review on
application of ultrasonic vibrations for die sinking
EDM, wire cut EDM and micro EDM. The review
focuses on modes of applying ultrasonic vibrations, its
effects on performance parameters, metallurgical effects
of surface generated, process modelling, analysis and
optimization and applications for advanced and
difficult-to-cut materials. Based on the review, future
research directions have been suggested to explore new
areas of ultrasonic vibration assistance in EDM.
Modes of applying ultrasonic vibrations to
EDM
Researchers have experimented with various modes to
employ ultrasonic vibrations in EDM system like vibra-
tions applied to workpiece, tool and wire and dielectric
fluid. This section of this article provides the review of
the above-mentioned modes.
Ultrasonic vibration applied to workpiece
Murthi and Philip6 have designed and fabricated an
ultrasonic fixture with magnetostrictive transducer
Downloaded from pib.sagepub.com by guest on May 6, 2015
operating at a resonance frequency of 22 kHz with 3-mm
amplitude. The authors reported that the influence of
ultrasonic on machining rate with drilling or cavity sink-
ing is highly remarkable on the EDM performance due
to improved stability of sparking because of ultrasonic
field forces and micro streaming. Gao and Liu7 devel-
oped a ultrasonic-assisted micro EDM system, where
the workpiece was directly attached to a piezoelectric
transducer to secure the vibration as shown in Figure
1(a). The results obtained show that ultrasonically aided
micro EDM gives eight times greater efficiency as com-
pared to conventional micro EDM. Hoang and Yang8
have experimented using piezoelectric actuator in micro
wire electric discharge machining (WEDM) for the
workpiece excited method as shown in Figure 1(b).
Comparative experimental results revealed that when
vibration is applied to the workpiece, the cutting rate is
1.5 times higher than when vibration is applied to the
wire and 2.5 times higher than in conventional WEDM.
Larger area of the workpiece is involved to circulate
dielectric and flush away the melted material in case of
workpiece vibration, resulting in higher machining effi-
ciency than vibration of the wire.
Ultrasonic vibration applied to tool and wire electrode
Kremer et al.9 used a vibrating system for investigation,
as shown in Figure 2(a), where one end was directly
connected to the head of EDM and the other end to
the electrode. It has been observed that vibrating tool
results in improved process performance compared to
non-vibrating tool EDM.
Kavtaradze et al.11 reported about superposition of
ultrasonic vibrations in wire electrode. Moreover,
Lipchanskii12 experimentally investigated the ultrasonic
vibration–assisted WEDM and found improvement in
process performance. Guo et al.10 have developed a
device consisting of a transducer, a wire holder and an
ultrasonic generator mounted on a WEDM as shown
in Figure 2(b) to study the vibration of the wire. The
wire was vibrated to 12 mm amplitude on 35 kHz fre-
quency to investigate the machining mechanism of
WEDM assisted by ultrasonic vibration of the wire. It
has been observed that ultrasonic vibration increases
the cutting efficiency of WEDM by 30% and reduce
Khatri et al. 3

Figure 2. (a) Ultrasonic vibrating EDM9 and (b) ultrasonic-aided WEDM set-up.10

Figure 3. (a) Ultrasonic bath in micro EDM13 and (b) ultrasonic sonotrode in micro EDM.14

the roughness of the machined surface remarkably. Yu

et al.13 presented a new method of combining ultraso-
nic vibration with planetary movement of an electrode
to drill micro-holes with high aspect ratios by micro
EDM for improvement of MRR.

Ultrasonic vibration supplied to dielectric fluid

Prihandana et al.14 have introduced the concept of
applying ultrasonic vibration to the dielectric fluid for
micro EDM processes as shown in Figure 3(a) wherein
ultrasonic vibration with frequency 43 kHz was used to
increase the kinetic energy of discharge debris in ultra-
sonically activated bath. The results indicated signifi-
cant increase in MRR and improved surface quality.
Schubert et al.15 reported about immersing vibrating Figure 4. Researches in ultrasonic vibration application to
sonotrode in the dielectric and arranged it in such a EDM variants.
way that the high intensity near the field of the ultrasonic
is aligned to the machining zone as shown in Figure 3(b),
which eventually increases the process speed. experimentally investigated the effect of applying ultra-
Ghiculescu et al.16 demonstrated an equipment for sonic vibrations to the machining fluid in micro EDM.
WEDM that increased machining rate by cavitation It was reported that a significant increase in the
effect produced through longitudinal oscillations of an machining speed was realized by applying ultrasonic
acoustic chain immersed in dielectric liquid. Dielectric vibration.
liquid contained in a hopper kept the relative position
between the workpiece and the electrode constant with- Remarks. Figure 4 shows research trends in ultrasonic
out affecting the precision. Ichikawa and Natsu17 have vibration application to different variants of EDM

Downloaded from pib.sagepub.com by guest on May 6, 2015

4 Proc IMechE Part B: J Engineering Manufacture
(EDM/WEDM/micro EDM). Ultrasonic vibration of
the workpiece affects large area and tends to increase
dielectric circulation and eventually flushing efficiency,
resulting higher machining efficiency than the vibration
of the wire.7 Moreover, the vibration of tool/wire
requires smaller piezoelectric ultrasonic device with
small size, low cost and low power consumption com-
pared to the vibration of the workpiece. While the
vibration to dielectric fluid creates pressure variation in
spark gap for better debris evacuation without change
in gap distance. All methods have potential to cater in
one or more aspects and have unique advantages com-
pared to other modes and hence have been tried at
different research levels.
Effects of ultrasonic vibrations on
performance parameters of EDM
Researchers have been working on understanding the
effects and benefits of ultrasonic vibrations on EDM,
micro EDM and WEDM since the last 25 years.5 Some
articles have been found related to beneficiary effects
of UVAEDM process in terms of influence on perfor-
mance parameters and metallurgical effects. This sec-
tion provides an insight into major performance
measures like MRR, tool wear rate (TWR), surface
roughness (SR), pulse characteristics and metallurgical
effects like recast layer and heat-affected zone thick-
ness, micro cracks and debris characteristics.
Effects on MRR
Murthi and Philip6 have compared the EDM planning
and EDM drilling operations with and without work-
piece vibration. It has been observed that the influence
of ultrasonic on MRR in case of EDM drilling is highly
remarkable. Kremer et al.9,18 have observed 400%
gains in MRR (shown in Figure 5) during finishing
operation by synchronizing the tool oscillations with
EDM discharges and improvement in the slurry circula-
tion. In addition, tool oscillating at high frequency gen-
erates pumping action by pushing the debris away and
sucking new fresh dielectric. Zhixin et al.19 have com-
pared MRR for UVAEDM with ultrasonic machining
(USM) and found that MRR of the combined machin-
ing is about three times more than that of USM. Zhang
et al.20 proposed EDM with tool vibration using direct
current (DC) power supply instead of the usual pulse
power supply and reported that MRR increased with
the increase in the amplitude of the tool face.
Ghoreishi and Atkinson21 have experimented with
high-frequency forced axial vibration of the electrode
with rotation (vibro-rotary) in EDM and found that
vibro-rotary movement increases MRR up to 35%
compared with vibration in semi-finishing operation.
Shervani-Tabar et al.22 introduced simultaneous vibra-
tion of the tool and the workpiece as a new idea in
ultrasonic-assisted EDM (UAEDM). It has been
Downloaded from pib.sagepub.com by guest on May 6, 2015
Figure 5. Effect on MRR due to ultrasonic vibration.16
reported that simultaneous ultrasonic vibration of the
tool and the workpiece produces higher MRR in com-
parison with the conventional EDM and UAEDM
with ultrasonic vibration of the tool. Guo et al.10,23
studied the machining mechanism of WEDM with
ultrasonic vibration of the wire and found that the
combined technology of ultrasonic-assisted WEDM
facilitates to form multiple channel discharge and raise
the utilization ratio of the energy that leads to the
improvement in cutting rate and the cutting efficiency
of WEDM by 30%. Table 1 shows summary of the
research finding by different authors.
Effect on TWR
Jiang et al.24 have experimentally compared conven-
tional EDM, UVAEDM and vibration-assisted EDM
using voice coil motor for TWR. The authors reported
that TWR is reduced remarkably for UAEDM, as
improved flushing gap status weakened erosion of tool
electrode (shown in Figure 6). Tong and Wang25 inves-
tigated TWR in micro EDM. The authors reported that
in the micro EDM assisted by workpiece vibration, an
increase in discharge frequency is directly proportional
to the vibration frequency. In addition, an increase in
effective discharge ratio results in more spark explosive
force to accelerate dielectric liquid circulation and deb-
ris removal, so that the tool electrode wear is improved.
Ichikawa and Natsu17 have experimentally investi-
gated the effect of applying ultrasonic vibration to the
machining fluid in micro EDM. It was found that a sig-
nificant increase in the machining speed was realized by
applying ultrasonic vibration. The experimental results
showed that the lateral gap width between the tool elec-
trode and workpiece was shortened, and the tool wear
ratio became smaller. Srivastava and Pandey26,27 used
cryogenic cooling for ultrasonically vibrating tool and
Khatri et al. 5

Table 1. Research findings of the literature reviewed for MRR.

Authors (year) Process Mode of application of Remarks (improvement in MRR)

ultrasonic

Murthi and Philip (1987)6
Kremer et al. (l991)9,18
Zhixin et al. (1997)19
Zhang et al. (1997)20
Ghoreishi and Atkinson (2002)21
Shervani-Tabar et al. (2013)22
Yu et al. (2009)13
Guo et al. (1997)10,23
ED planning Ultrasonic vibration to MRR significantly increases with
and drilling tool ultrasonic, but machining rate rise in
drilling is more compared to planning
operations.
ED drilling Ultrasonic vibration to MRR gains in range 10%–400% due to
tool better pumping action.
ED drilling Ultrasonic vibration to MRR gains by 200% due to over 80%
tool efficient discharge pulse.
EDM Ultrasonic vibration to MRR increases with increase in voltage
tool and amplitude of vibration.
Vibro-rotary EDM Axial ultrasonic vibration MRR gains by 600% in vibro-rotary EDM
to rotary tool compared to rotary EDM.
EDM Simultaneous ultrasonic Simultaneous ultrasonic vibration causes
vibration of tool and better evacuation of debris from the gap
workpiece and causes more MRR in comparison with
the conventional EDM and with the case
of ultrasonic-assisted EDM with ultrasonic
vibration of the tool.
Micro EDM Ultrasonic vibration of MRR for ultrasonic EDM is 6359 mmm3/S
workpiece compared to 3948 mmm3/S for EDM.
Wire EDM Ultrasonic vibration of Cutting efficiency increased by 30% in
wire ultrasonic wire EDM compared to simple
wire EDM.

ED: electric discharge; MRR: material removal rate; EDM: electric discharge machining.

the vibrating worktable for micro EDM and found that

the vibration machining technique improves the effi-
ciency of micro EDM significantly. The number of
effective sparks in vibration EDM increased noticeably.
Larger feed and better surface finish can be achieved in
micro EDM with vibration machining. Guo et al.10
observed that SR reduced with the application of ultra-
sonic to wire in WEDM.

Effect on pulse characteristics

Figure 6. Effect on TWR due to ultrasonic vibration.24
established that TWR reduced in ultrasonic-assisted
cryo cooled EDM process. Table 2 shows summary of
the research finding by different authors.
Stability of EDM process can be evaluated by checking
pulse train characteristics. Murthi and Philip30 pre-
sented a method of pulse train analysis in case of
UVAEDM. The authors categorized EDM pulses as
effective (pulses with low ignition delay, pulses with
medium ignition delay and pulses with large ignition
delay) and ineffective pulses (short-circuit pulse, open-
circuit pulse and arcing) for detailed analysis. It has
been experimentally confirmed that the flushing is
highly influenced by ultrasonic vibrations which
causes reduction in ineffective pulses (shorts and arc-
ing), thus indicates improvement in the sparking
efficiency.

Effect on SR
Abdullah and Shabgard28 observed that about 10%
rougher surface is obtained when using ultrasonic
vibrations due to more molten material being ejected
by every discharge and also due to deeper and wider
craters. Chern and Chuang29 designed and developed
Remarks. Detailed analysis has been carried out for the
referred works stated in the article for evaluation of the
critical information regarding improvement of various
performance parameters. It has been pointed out that
application of ultrasonic vibrations improve MRR and
decreases TWR significantly, which in turn enhances

Downloaded from pib.sagepub.com by guest on May 6, 2015

6 Proc IMechE Part B: J Engineering Manufacture
Table 2. Research findings of the literature reviewed for TWR.
Authors (year) Process
Jiang et al. (2012)24 ED drilling
Tong et al. (2008)25 Micro EDM
Ichikawa and Natsu (2013)17 Micro EDM
Srivastava and Pandey (2012)26,27 Cryo cooled EDM
ED: electric discharge; TWR: tool wear rate; EDM: electric discharge machining.
Figure 7. Scanning electron micrographs of EDM debris: (a) without ultrasonic and (b) with ultrasonic.32
production economy of the EDM process. Moreover,
surface finish and sparking efficiency improve when
EDM process is assisted by ultrasonic vibrations.
Effects of ultrasonic vibrations on
metallurgical characteristics
During EDM process, melting and solidification of
molten debris alter material surface characteristic in the
heat-affected zone, which consists of white, tempered
and reheated layers. Kremer et al.9 have reported that
due to better debris ejection from sparking gap, lesser
material recast is leading to thinner heat-affected zone
and minimum metallurgical changes in the surface.
Fewer micro cracks on the work material surface
increase fatigue life by two to six times. Singh et al.31
reported the major difference between continuous- and
discontinuous vibration–assisted EDM in terms of size
and number of micro cracks appearing on the machined
surface. The authors have observed that in discontinu-
ous vibration–assisted EDM, small cracks are observed
Downloaded from pib.sagepub.com by guest on May 6, 2015
Mode of application of Remarks (improvement in TWR)
ultrasonic
Ultrasonic vibration to Significance reduction of TWR from 23% to
workpiece 6% due to improved gap status and lesser
tool electrode erosion.
Ultrasonic vibration to Machining depth observation indicates lesser
workpiece TWR for ultrasonic EDM compared to
normal EDM.
Ultrasonic vibration to TWR reduces due to reduction in short
dielectric fluid circuits and abnormal discharges caused by
applying vibration.
Ultrasonic vibration to Smaller size of the crater formed due to cryo
tool cooled tool tip and also increase the recast
layer in the tool, therefore tool wear
reduces.
due to less volume of re-solidified material in each cra-
ter which gets quenched with the surrounding dielectric
leaving a rougher surface with small micro cracks.
Dielectric fluid removes the molten material in the
form of microscopic debris after each discharge from
spark gap in order to avoid short circuit. For stable and
efficient machining, production rate of debris must be
equal to its flushing rate. Debris analysis is required for
better understanding of the erosion mechanism. Murthi
and Philip32 collected debris using ceramic ring magnet
around machining zone and examined the effects of
ultrasonic vibration of the workpiece on debris charac-
teristics (size, shape, distribution) by using scanning
electron microscope (SEM). The debris in case of ultra-
sonic EDM was found to be globular in shape and solid
except a few isolated hollow particles, compared to that
of without ultrasonic as shown in Figure 7. The authors
reported the larger debris particles produced due to the
increased collisions between molten droplets. Also, the
size distribution was near normal, indicating the
stochastic nature of particle formation.
Khatri et al.
Remarks. Ultrasonic vibrations help molten globules to
get detached easily and form smaller size and spherical
shape. It results in thinner heat-affected zone and hence
smaller surface micro cracks.
Process modelling of UAEDM
The EDM process is of stochastic thermal nature hav-
ing highly complex discharge mechanism. However,
researchers have developed mathematical models for
process analysis to understand the effect of operating
variables on achieving the desired machining character-
istics. Murthi and Philip6 have established an empirical
relationship of machining responses using response sur-
face methodology (RSM) technique while machining
using ultrasonic vibration of the workpiece. The results
showed that the machining rate, surface finish and
TWR improved significantly. However, the wear ratio
was not influenced significantly. Shabgard et al.33 pre-
sented a systematic methodology for developing statisti-
cal models to show the relationship between important
machining performance parameters (MRR, tool wear
ratio and SR) and input machining parameters (pulse
current and pulse on time) in the EDM and UAEDM
of tungsten carbide (WC). The results showed that
MRR increased significantly in UAEDM of cemented
WC (WC–10% Co), especially in finishing modes and
can be up to four times greater than that of conven-
tional EDM. Shervani-Tabar and Abdullah34 numeri-
cally and experimentally investigated the effects of tool
vibrations in UVAEDM and reported that MRR
increased in both cases.
Marinescu et al.35 reported about modelling of mate-
rial removal mechanism and attempted to explain about
ultrasonic-induced thermal and cavitation phenomenon
in the spark gap in EDM process. Increased number of
discharges within an oscillation period resulted in
increased material removal due to ultrasonically
induced cavitation. Zhang et al.36 studied an adaptive
fuzzy control system of servo mechanism for electro-
discharge machining with ultrasonic to adjust discharge
pulse parameter in a timely manner and machining gap
to optimize the machining state and to improve the
machining efficiency. Shabgard et al.37 developed fuzzy
models for the selection of the UAEDM parameters for
WC (WC–10% Co). It was observed that the fuzzy
modelling results were in good agreement with the
experimental findings demonstrating approximately
90% predictions complying. Fuzzy modelling technique
could be an economical and successful method for pre-
diction of output parameters according to input vari-
ables. Sundaram et al.38 presented an investigation on
the optimization of machining parameters on MRR
and tool wear in ultrasonic-assisted micro EDM by
using Taguchi method. The significance of the para-
meters on MRR and tool wear was determined by using
analysis of variance (ANOVA). ANOVA was per-
formed and signal-to-noise (S/N) ratio was determined
Downloaded from pib.sagepub.com by guest on May 6, 2015
7
to know the level of importance of the machining para-
meters. Mohammadi et al.39 analysed the effects of
ultrasonic vibration, discharge power, off-time and
rotational speed on MRR for a new method of vibra-
tion transfer to the wire in ultrasonic-assisted wire elec-
trical discharge turning. The authors have reported that
higher MRR is mainly due to reduction in friction
between the wire and the wire guide that causes reduc-
tion in wire breakage, improvement in flushing and cre-
ation of suction on the molten material crater, resulting
in a greater MRR. Ghiculescu et al.40 carried out
researches concerning modelling of material removal
mechanism at micro-geometric level by computer-aided
finite element method (FEM) of ultrasonic-aided
EDM. Qualitative and quantitative analyses of
machined surface by UAEDM process of Al–Zn–Mg
aluminium alloy have shown improvement in surface
layer and wear resistance.41Table 3 shows summary of
the research finding by different authors.
Remarks. Physics of EDM process is governed by
intense thermal and pressure effects, shock wave propa-
gation theories due to bubble formation and bursting
phenomenon, ultrasonic wave theories and metallurgi-
cal phenomenon like melting solidification, evaporation
and fluid mechanics. The models developed to under-
stand the process behaviour are limited to few physics
theories only at a time neglecting influence of other the-
ories. There are no process models, which are accepta-
ble in entire EDM domain. Advanced engineering tools
along with computational techniques have the capabil-
ity to correlate all the physics aspects to develop a more
accepted and better representative process model.
UVAEDM in gas
EDM operations have been experimented using gaseous
dielectrics like oxygen42 and compressed air,43 with a
view to reduce environmental pollution and improve
some performance characteristics as compared to liquid
dielectrics. However, gaseous dielectrics have limita-
tions like low stability and low MRR.44 Zhang et al.45
have experimented with UVAEDM in gas by using
thin-walled pipe electrode for supplying gas (air, oxy-
gen) through hole and ultrasonic vibrating workpiece.
It has been observed that higher MRR can be achieved
for UAEDM with gas as compared to EDM with gas
and EDM with liquid. Kunieda et al.46 described
improvement of the machining characteristics of dry
EDM by controlling the discharge gap distance using a
piezoelectric actuator. Zhang et al.47 studied the effects
of open voltage, pulse duration, discharge current and
amplitude of ultrasonic vibration on MRR and devel-
oped a theoretical model to estimate MRR. Zhang
et al.48 carried out experimental comparative study of
performance for EDM in kerosene, EDM in gas and
UEDM in gas and concluded that the effectiveness of
EDM in gas can be improved with the help of
 Table 3. Research findings of the literature reviewed for process modelling.
8
Authors (year) Techniques of modelling Focus of modelling Assumptions for Outcomes/equations Comments
modelling

Murthi and Philip Response surface Machining characteristics Second-order polynomial From response surface plots, Unstable sparking due to excessive
(1987)6 methodology comparison due to is sufficient for response machining rate significantly increased concentrations of chips in case of
influence of ultrasonic in surface. under influence of ultrasonic in drilling planning comparing to drilling leads to
planning and drilling compared to planning operation. decreased significance of ultrasonic
operations in EDM Tool wear rate increased under effect.
influences of ultrasonic. Cumulative effect of better sparking
efficiency and less incidence of arcing
In MRRUS=EDM contribute to tool wear rate.
Shabgard et al. Regression analysis Mathematical statistical Logarithmic Regression analysis for cemented
(2009)33 modelling of ultrasonic transformations were In MRREDM tungsten carbide also correlates
EDM and comparison selected with only two = 1:6935 0:0252(I) 0:0296(Ti ) experimentally increases in MRR due
with EDM input variables (pulse where I = Current to improved dielectric circulation in
current and pulse on case of ultrasonic.
Ti = pulse on time
time).
Shervani-Tabar and Numerical analysis by Dynamic behaviour of The materials of Proper synchronization in frequencies Maximum volume expansion and life
Abdullah (2007)34 boundary integral vapour bubble in spark workpiece, tool and of electric discharge and tool vibration time of vapour bubble due to closet
equation gap dielectric are not increases MRR as per prediction of position of electric discharge to
chemically active. numerical results. workpiece and tool leads to highest
Problem is considered MRR.
axisymmetric.
Marinescu et al. Empirical modelling Combine thermal- All bubbles from the gap The bubble surrounding plasma The stability of EDM + ultrasonic
(2009)35 cavitation phenomena collapse, generating shock channel has short life in finishing process was obtained
waves parallel to EDM + ultrasonic; the cumulative increasing the working gap through
machined surface. micro jets removing almost all ignition voltage growing and amplitude
materials melted by discharge. decrease of ultrasonic oscillations.
Zhang et al. Adaptive fuzzy logic Spark gap analysis Adaptive fuzzy control Optimum machining state by weight Fuzzy control system able to adjust
(2002)36 system for step frequency average judgement. discharge parameters and the gap for
only. better performance.

Downloaded from pib.sagepub.com by guest on May 6, 2015

Shabgard et al. Fuzzy rule–based system Process parameter – Triangular and trapezoidal membership The fuzzy modelling results were in
(2013)37 selection function shapes gave better results good agreement with experiments
matching with experimentation. with 90% prediction achievement.
Sundaram et al. Analysis of variance Contribution of each The residual error is S/N ratio was determined to know the The ultrasonic vibration results in
(2008)38 variable on output in normal. level of importance of the machining widened gap which leads to larger
micro EDM parameters in micro EDM. pressure drop resulting in higher
removal rate.
Mohammadi et al. Statistical software Effects of ultrasonic The residual error is Better process stability due to better Ultrasonic vibration of the wire
(2013)39 MINITAB and analysis of vibration and rotational normal. debris suspension and evacuation from creates micro bubbles and intensive
variance speed on MRR in WEDT the gap and better dielectric fluid ejecting micro streams, accelerates
renewal. mass transfer across the spark gap,
acting as a pump.
Ghiculescu et al. Finite element method Micro geometry Constant surface FEM results confirm the increase in Orientation of cumulative micro jets
(2009)40 micro geometry behaviour at thermal temperature and constant machining rate with up to 500%. The parallel to machined surface removes
modelling attack produced by output thermal flux types improvement of surface roughness is micro geometry peaks by ultrasonic
discharges under of boundary condition up to 50%. shearing and improves surface
conditions were taken. roughness.
Proc IMechE Part B: J Engineering Manufacture

EDM: electric discharge machining; MRR: material removal rate; S/N: signal-to-noise; FEM: finite element method; WEDT: wire electric discharge turning.
Khatri et al. 9

Table 4. Research findings of the literature reviewed for ultrasonic in gas.

Author Year Research details in ultrasonic EDM in gas

Zhang et al. 2002 Rotary thin-walled pipe tool having high-pressure gas from hole and vibrating at ultrasonic
frequency in EDM was used for dry condition.45
2004 Mathematically modelled material removal mechanism of UEDM in gas and analysis of effects of
open voltage, pulse duration, discharge current, pipe wall thickness and amplitude of ultrasonic
vibration on MRR.47
2006 Mathematically modelled surface roughness formation mechanism of UEDM in gas and
comparative analysis for EDM in kerosene, EDM in gas and UEDM in gas.48
Kunieda et al. 2004 Developed piezoelectric gap control system for improvement of dry EDM performances.46
Xu et al. 2009 Five material removal mechanisms and micro analysis of cemented carbides machined by UEDM in
gas.49

EDM: electric discharge machining; MRR: material removal rate; UEDM: Ultrasonic EDM.

ultrasonic actuation although the increase in MRR was
at the expense of SR. Xu et al.49 demonstrated EDM
using vibrating tool instead of the workpiece and
observed that ultrasonic EDM with tool vibration in
gas media is a suitable method for machining cemented
carbides. Table 4 shows the summary of research find-
ings of other researchers on using UVAEDM in gas.
Remarks. Introduction of gaseous dielectrics in EDM
was mainly aimed to improve environmental and oper-
ator friendliness of the process. However, inefficient
debris ejection from the sparking gap raised some tech-
nical issues affecting process economics and surface
quality. Applications of ultrasonic vibrations have
demonstrated improvement in those issues.
UAEDM for advanced and difficult-to-cut
materials
The EDM of advanced ceramics has been widely
accepted by the metal cutting industry owing to the
competitive machining costs and features.1 Lee et al.50
carried out experimental investigation on the effect on
MRR and SR generated by UAEDM on ceramics. The
main objective was to compare ultrasonic, EDM and
combined UAEDM. It has been found that MRR for
UAEDM is a little more than just the sum of MRR for
USM and EDM, while SR for UAEDM is about the
same as that for USM. Thoe et al.51 drilled 1-mm-dia-
meter single hole using various tool materials (tungsten,
silver steel, mild steel and copper) on ceramic-coated
nickel alloy with UAEDM. The results highlighted that
mild steel is the most resilient, whereas the other mate-
rials fail because of fatigue fracture or deformation.
Titanium alloy (Ti–6Al–4V) can be classified as a
difficult-to-cut material, not suitable for traditional
machining. The combination of EDM/USM process
has been investigated in machining titanium alloy, com-
paring conventional.52 MRR of the combination
EDM/USM process is higher than the conventional
EDM. Wansheng et al.53 introduced ultrasonic vibra-
tion into micro EDM for deep hole drilling in Ti–6Al–
4V workpiece material.
Among the difficult-to-cut materials, WC is an
extremely hard material used extensively in manufac-
turing because of its superior wear and corrosion resis-
tance.54 Shabgard et al.55 proved that ultrasonic
vibration of the tool could significantly improve the
surface integrity of cemented WC (WC–10% Co) in the
EDM process. Jahan et al.56 presented the vibration-
assisted micro EDM of WC, where the workpiece is
subjected to low-frequency vibration. Iwai et al.57
investigated machinability of polycrystalline diamond
(PCD) using ultrasonic vibrations to copper electrode.
The experimental results revealed that EDM efficiency
increased by three times than the ordinary EDM.
Combining electrical discharges and ultrasonic-assisted
mechanical means is an ideal method suitable for PCD
materials.58
The effects of the EDM combined with the ultraso-
nic vibration for machining Si3N4 were investigated.59
MRR of the UVAEDM was about two times higher
than that for the normal EDM for the range of the
ultrasonic frequency between 17 and 25 kHz.
Remarks. Processing of advanced and difficult-to-cut
materials is one of the main application areas for EDM
domain. Each type of material has its unique process-
ing limitations and requirements. Ultrasonic vibration
assistance has proved to be an effective and successful
means to improve fatigue behaviour, tribological per-
formance and wear characteristics of advanced and
difficult-to-cut materials.
Concluding remarks
The study about UVAEDM has been undertaken since
mid-1980s.60 The authors in this article have reviewed
and highlighted the progress of UVAEDM process
from 1987 to 2013 including dry ultrasonic EDM as
shown in Figure 8.
Researches done so far on UAEDM and its variants
like WEDM and micro EDM are at the primitive level
only, and detailed process behaviour data are not
reported properly. An insight into the research litera-
tures available has revealed that there are areas where

Downloaded from pib.sagepub.com by guest on May 6, 2015

10
Figure 8. The progress of ultrasonic vibration–assisted EDM from 1987 to 2013.
technological research is yet to be carried out and there
is immense potential to take the EDM process closer to
one-step solution for material processing. Some of the
future research needs have been highlighted as below.
Future research directions
Based on the review carried out by the authors in this
article, some research gaps have been observed and sug-
gested as future research directions as discussed below.
 Ultrasonic-assisted electric discharge milling
Manufacturing of three-dimensional (3D) cavities
with electric discharge milling is possible for simple
geometrical features only due to inefficiency of debris
flushing from sharp corners and intricate features. In
addition, tapering, corner rounding and skewing-
related issues lead to uneven material removal from
work as well as electrode surface. Ultrasonic-assisted
electric discharge milling is likely to provide better
flushing, uniform dispersion of debris in the dielectric
by preventing formation of debris bridge and
conglomeration.
 Computational fluid dynamics modelling of plasma
channel formation and bursting for ultrasonic EDM
No work has yet been found on computational fluid
dynamics (CFD) model for UAEDM. The model
developed is likely to understand the exact phenom-
enon of pressure wave propagation and debris
Downloaded from pib.sagepub.com by guest on May 6, 2015
Proc IMechE Part B: J Engineering Manufacture
detachment, dispersion and evacuation phenomenon.
The model may be used for selection of flushing tech-
nique for an application.
 Powder mixed UVAEDM
Powder and additive mixing with dielectric has shown
its positive influential role to improve process perfor-
mance. Application of ultrasonic vibrations results into
charging and activation of the powder suspending into
dielectric media and ensure uniform suspension and
prevent conglomeration to ensure stable and favour-
able sparking cycles. This technique may be used for
uniform and increased metal accretion/deposition rate
for coating and other surface treatments.
 Ultrasonic-assisted dry and near-dry EDM
Researchers have reported that debris reattachment,
poor debris ejection and non-uniform erosion rates are
some of the issues still to be addressed for dry and near-
dry EDM processes. Ultrasonic vibration assistance in
dry and near-dry EDM processes is likely to address
the above-mentioned issues.
Acknowledgements
The authors would like to acknowledge the support
and motivation from Commissionerate of Technical
Education, Gujarat State, and R. K. University,
Gujarat State. The authors are also thankful to all
those who contributed, supported and motivated
directly or indirectly for carrying out research.
Khatri et al.
Declaration of conflicting interests
The authors declare that there is no conflict of interest.
Funding
This research received no specific grant from any fund-
ing agency in the public, commercial or not-for-profit
sectors.
References
1. Ho KH and Newman ST. State of the art electrical dis-
charge machining (EDM). Int J Mach Tool Manu 2003;
43: 1287–1300.
2. Leao FN and Pashby IR. A review on the use of
environmentally-friendly dielectric fluids in electrical dis-
charge machining. J Mater Process Tech 2004; 149:
341–346.
3. Endo T, Tsujimoto T and Mitsui K. Study of vibration-
assisted micro-EDM – the effect of vibration on machin-
ing time and stability of discharge. Precis Eng 2008; 32:
269–277.
4. Lauwers B. Surface integrity in hybrid machining pro-
cesses. Procedia Engineering (First CIRP conference on
surface integrity) 2011; 19: 241–251.
5. Zhixin J, Jianhua Z and Xing A. Ultrasonic vibration
pulse electro-discharge machining of holes in engineering
ceramics. J Mater Process Tech 1995; 53: 811–816.
6. Murthi VSR and Philip PK. A comparative analysis of
machining characteristics in ultrasonic assisted EDM by
the response surface methodology. Int J Prod Res 1987;
25(2): 259–272.
7. Gao C and Liu Z. A study of ultrasonically aided micro-
electrical-discharge machining by the application of
workpiece vibration. J Mater Process Tech 2003; 139:
226–228.
8. Hoang KT and Yang SH. A study on the effect of differ-
ent vibration-assisted methods in micro-WEDM. J
Mater Process Tech 2013; 213: 1616–1622.
9. Kremer D, Lebrun JL, Hosari B, et al. Effects of ultraso-
nic vibrations on the performances in EDM. CIRP Ann:
Manuf Techn 1989; 38(1): 199–202.
10. Guo ZN, Lee TC, Yue TM, et al. A study of ultrasonic-
aided wire electrical discharge machining. J Mater Pro-
cess Tech 1997; 63: 823–828.
11. Kavtaradze ON, Lipchanskii AB and Nechaev GG.
Vibration of wire electrode during electroerosion machin-
ing with the superposition of ultrasonic vibrations. Sov
Surf Eng Appl Electrochem 1989; 4: 13–17.
12. Lipchanskii AB. Experimental investigation of wire elec-
trical discharge machining assisted with ultrasonic vibra-
tion. Sov Surf Eng Appl Electrochem 1991; 1: 5–9.
13. Yu ZY, Zhang Y, Li J, et al. High aspect ratio micro-
hole drilling aided with ultrasonic vibration and plane-
tary movement of electrode by micro-EDM. CIRP Ann:
Manuf Techn 2009; 58: 213–216.
14. Prihandana GS, Mahardika M, Hamdi M, et al. Effect
of micro-powder suspension and ultrasonic vibration of
dielectric fluid in micro-EDM processes – Taguchi
approach. Int J Mach Tool Manu 2009; 49(12–13): 1035–
1041.
15. Schubert A, Zeidler H, Hackert-Oschätzchen M, et al.
Enhancing micro-EDM using ultrasonic vibration and
Downloaded from pib.sagepub.com by guest on May 6, 2015
11
approaches for machining of non-conducting ceramics. J
Mech Eng 2013; 59(3): 156–164.
16. Ghiculescu D, Marinescu NI and Nanu S. Equipment
for ultrasonic aiding of wire electrodischarge machining.
Acad J Manuf Eng 2011; 9(2): 18–23.
17. Ichikawa T and Natsu W. Realization of micro-EDM
under ultra-small discharge energy by applying ultrasonic
vibration to machining fluid. Procedia CIRP 2013; 6:
326–331.
18. Kremer D, Lhiaubet C and Moisan A. A study of the
effect of synchronizing ultrasonic vibrations with pulses.
CIRP Ann: Manuf Techn 1991; 40(1): 1–4.
19. Zhixin J, Jianhua Z and Xing A. Study on a new kind of
combined machining technology of ultrasonic machining
and electrical discharge machining. Int J Mach Tool
Manu 1997; 37(2): 193–199.
20. Zhang JH, Lee TC, Lau WS, et al. Spark erosion with
ultrasonic frequency. J Mater Process Tech 1997; 68:
83–88.
21. Ghoreishi M and Atkinson J. A comparative experimen-
tal study of machining characteristics in vibratory, rotary
and vibro-rotary electro-discharge machining. J Mater
Process Tech 2002; 120: 374–384.
22. Shervani-Tabar MT, Maghsoudi K and Shabgard MR.
Effects of simultaneous ultrasonic vibration of the tool
and the workpiece in ultrasonic assisted EDM. Int J Com-
put Meth Eng Sci Mech 2013; 14(1): 1–9.
23. Guo ZN, Lee TC, Yue TM, et al. Study on the machin-
ing mechanism of WEDM with ultrasonic vibration of
the wire. J Mater Process Tech 1997; 69: 212–221.
24. Jiang Y, Zhao W, Xi X, et al. Vibration assisted EDM of
small-hole using voice coil motor. Procedia CIRP 2012; 1:
645–650.
25. Tong H, Li Y and Wang Y. Experimental research on
vibration assisted EDM of micro-structures with non-
circular cross-section. J Mater Process Tech 2008; 208:
289–298.
26. Srivastava V and Pandey PM. Effect of process para-
meters on the performance of EDM process with ultraso-
nic assisted cryogenically cooled electrode. J Manuf
Process 2012; 14(3): 393–402.
27. Srivastava V and Pandey PM. Experimental investigation
on electrical discharge machining process with ultrasonic-
assisted cryogenically cooled electrode. Proc IMechE,
Part B: J Engineering Manufacture 2013; 227: 301–314.
28. Abdullah A and Shabgard MR. Effect of ultrasonic
vibration of tool on electrical discharge machining of
cemented tungsten carbide (WC-Co). Int J Adv Manuf
Tech 2008; 38: 1137–1147.
29. Chern G and Chuang Y. Study on vibration-EDM and
mass punching of micro-holes. J Mater Process Tech
2006; 180: 151–160.
30. Murthi VSR and Philip PK. Pulse train analysis in ultra-
sonic assisted EDM. Int J Mach Tool Manu 1987; 27(4):
469–477.
31. Singh J, Walia RS, Satsangi PS, et al. Hybrid electric dis-
charge machining process with continuous and discontin-
uous ultrasonic vibrations on workpiece. Int J Mech Syst
Eng 2012; 2(1): 22–33.
32. Murthi VSR and Philip PK. An analysis of the debris in
ultrasonic-assisted electrical discharge machining. Wear
1987; 117: 241–250.
33. Shabgard MR, Farahmand MR and Ivanov A. Mathe-
matical modelling and comparative study of the
12
machining characteristics in ultrasonic-assisted electrical
discharge machining of cemented tungsten carbide (WC–
10%Co). Proc IMechE, Part B: J Engineering Manufac-
ture 2009; 223: 1115–1126.
34. Shervani-Tabar MT and Abdullah A. Numerical and
experimental study on the effect of vibration of the tool
in ultrasonic assisted EDM. Int J Mach Tool Manu 2007;
32: 719–731.
35. Marinescu NI, Ghiculescu D and Jitianu G. Solutions for
technological performances increasing at ultrasonic aided
electrodischarge machining. Int J Mater Form 2009; 2:
681–684.
36. Zhang JH, Zhang H, Su DS, et al. Adaptive fuzzy con-
trol system of a servomechanism for electro-discharge
machining combined with ultrasonic vibration. J Mater
Process Tech 2002; 129: 45–49.
37. Shabgard MR, Badamchizadeh MA, Ranjbary G, et al.
Fuzzy approach to select machining parameters in electri-
cal discharge machining (EDM) and ultrasonic-assisted
EDM processes. J Manuf Syst: Soc Manuf Eng 2013;
32(1): 32–39.
38. Sundaram MM, Pavalarajan GB and Rajurkar KP. A
study on process parameters of ultrasonic assisted micro
EDM based on Taguchi method. J Mater Eng Perform
2008; 17: 210–215.
39. Mohammadi A, Tehrani AF and Abdullah A. Introdu-
cing a new technique in wire electrical discharge turning
and evaluating ultrasonic vibration on material removal
rate. Procedia CIRP 2013; 6: 583–588.
40. Ghiculescu D, Marinescu NI and Nanu S. Modelling
aspects of removal mechanism at ultrasonic aided electro-
discharge machining. Int J Mater Form 2009; 2: 685–688.
41. Lin YC, Yan BH and Huang FT. Surface modification
of Al-Zn-Mg aluminum alloy using the combined pro-
cess of EDM with USM. J Mater Process Tech 2001;
115: 359–366.
42. Kunieda M and Furuoya S. Improvement of EDM effi-
ciency by supplying oxygen gas into gap. CIRP Ann:
Manuf Techn 1991; 40(1): 215–218.
43. Kunieda M and Yoshida M. Electrical discharge machin-
ing in gas. CIRP Ann: Manuf Techn 1997; 46(1): 143–146.
44. Kunieda M, Miyoshi Y, Takaya T, et al. High speed 3D
milling by dry EDM. CIRP Ann: Manuf Techn 2003;
52(1): 147–150.
45. Zhang QH, Zhang JH, Deng JX, et al. Ultrasonic vibra-
tion electrical discharge machining in gas. J Mater Pro-
cess Tech 2002; 129: 135–138.
46. Kunieda M, Takaya T, Nakano S, et al. Improvement of
dry EDM characteristics using piezoelectric actuator.
CIRP Ann: Manuf Techn 2004; 53: 183–186.
Downloaded from pib.sagepub.com by guest on May 6, 2015
Proc IMechE Part B: J Engineering Manufacture
47. Zhang QH, Zhang JH, Ren SF, et al. Study on technol-
ogy of ultrasonic vibration aided electrical discharge
machining in gas. J Mater Process Tech 2004; 149:
640–644.
48. Zhang QH, Du R, Zhang JH, et al. An investigation of
ultrasonic-assisted electrical discharge machining in gas.
Int J Mach Tool Manu 2006; 46: 1582–1588.
49. Xu MG, Zhang JH, Li Y, et al. Material removal
mechanisms of cemented carbides machined by ultrasonic
vibration assisted EDM in gas medium. J Mater Process
Tech 2009; 209: 1742–1746.
50. Lee TC, Zhang JH and Lau WS. Machining of engineer-
ing ceramics by ultrasonic vibration assisted EDM
method. Mater Manuf Process 1998; 13(1): 133–146.
51. Thoe TB, Aspinwall DK and Killey N. Combined ultra-
sonic and electrical discharge machining of ceramic-
coated nickel alloy. J Mater Process Tech 1999; 93:
323–328.
52. Lin YC, Yan BH and Chang YS. Machining characteris-
tics of titanium alloy (Ti-6Al-4V) using a combination
process of EDM with USM. J Mater Process Tech 2000;
104: 171–177.
53. Wansheng Z, Zhenlong W, Shichun D, et al. Ultrasonic
and electric discharge machining to deep and small hole
on titanium alloy. J Mater Process Tech 2002; 120: 3–8.
54. Jahan MP, Rahman M and Wong YS. A review on the
conventional and micro-electrodischarge machining of tung-
sten carbide. Int J Mach Tool Manu 2011; 51(12): 837–858.
55. Shabgard MR, Farahmand MR and Ivanov A. Effect of
ultrasonic-assisted EDM on the surface integrity of
cemented tungsten carbide (WC-Co). Int J Adv Manuf
Tech 2009; 41: 268–280.
56. Jahan MP, Rahman M and Wong YS. Evaluation of the
effectiveness of low frequency workpiece vibration in
deep-hole micro-EDM drilling of tungsten carbide. J
Manuf Process 2012; 14(3): 343–359.
57. Iwai M, Ninomiya S and Suzuki K. Improvement of
EDM properties of PCD with electrode vibrated by ultra-
sonic transducer. Procedia CIRP 2013; 6: 146–150.
58. Qinjian Z, Luming Z, Jianyong L, et al. Study on electri-
cal discharge and ultrasonic assisted mechanical com-
bined machining of polycrystalline diamond. Procedia
CIRP 2013; 6: 589–593.
59. Praneetpongrung C, Fukuzawa Y, Nagasawa S, et al.
Effects of the EDM combined ultrasonic vibration on the
machining properties of Si3N4. Mater Trans 2010; 51(11):
2113–2120.
60. Abbas NM, Soloman DG and Bahari MF. A review on
current research trends in electrical discharge machining
(EDM). Int J Mach Tool Manu 2007; 47: 1214–1228.