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<p>The integration of rotary wire electrical discharge machining (WEDM) technology broadens its applicability from two-dimensional to cylindrical part machining, enabling the production of complex geometries with high precision. In this study, an ultrasonic vibro-rotary spindle was designed, assembled and evaluated to enhance the machining capabilities of WEDM for cylindrical components. The ultrasonic spindle facilitates both rotational motion and high-frequency vibration, which improves debris removal and enhances machining stability. Experimental results demonstrate that incorporating ultrasonic vibration into the spindle design increases the material removal rate (MRR) and reduces surface roughness across various machining paths, such as straight and tapered turning operations. Specifically, the MRR was improved by 2.9%, and surface roughness was improved, ranging from 2.5% to 30.3%, depending on the machining path that was proposed. These findings highlight the potential of ultrasonic-assisted rotary WEDM as a viable technique for high-precision machining of cylindrical components. This aligns with advancements in manufacturing technologies and the growing demand for intricate geometries.</p>

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Evaluation of an Ultrasonic Vibro-Rotary Spindle for Wire Electrical Discharge Machining in Machining Cylindrical Shape Parts

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年6月10日

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  • M. A. M. Zakaria,
  • R. Izamshah,
  • M. S. Kasim

摘要

The integration of rotary wire electrical discharge machining (WEDM) technology broadens its applicability from two-dimensional to cylindrical part machining, enabling the production of complex geometries with high precision. In this study, an ultrasonic vibro-rotary spindle was designed, assembled and evaluated to enhance the machining capabilities of WEDM for cylindrical components. The ultrasonic spindle facilitates both rotational motion and high-frequency vibration, which improves debris removal and enhances machining stability. Experimental results demonstrate that incorporating ultrasonic vibration into the spindle design increases the material removal rate (MRR) and reduces surface roughness across various machining paths, such as straight and tapered turning operations. Specifically, the MRR was improved by 2.9%, and surface roughness was improved, ranging from 2.5% to 30.3%, depending on the machining path that was proposed. These findings highlight the potential of ultrasonic-assisted rotary WEDM as a viable technique for high-precision machining of cylindrical components. This aligns with advancements in manufacturing technologies and the growing demand for intricate geometries.