The EDM technique uses pulsed spark discharge between the electrode and the workpiece in a certain working medium to remove the material to be machined and finally achieve the desired shape, size and surface topography[1–2]. Compared with conventional machining methods, EDM technology has the advantage of not being limited by the hardness and strength requirements of the workpiece material[3–4]. It is widely used in the machining of difficult materials such as high hardness, high toughness, high brittleness and any conductive materials, and the machining of micro-porous and complex shapes has become an indispensable machining method at this stage[5–6].
Due to the huge inertia of the mechanical transmission system, the conventional EDM using a motor and ball screw actuator is slow to respond and cannot guarantee the ideal inter-pole gap in time[7], resulting in unstable inter-pole voltage for EDM, which affects the discharge probability, thus limiting the efficiency and accuracy of conventional EDM. Compared with traditional cutting methods, the efficiency of EDM does not have an advantage, so it is necessary to find ways to improve the efficiency of EDM.
To improve the efficiency of EDM, research scholars have done a lot of research on improving the efficiency of EDM according to the principle of EDM and discharge mechanism, including increasing the rotation and vibration of the electrode to promote chip removal, adjusting the gap voltage to increase the probability of spark discharge, combining ultrasonic vibration technology in EDM, increasing the magnetic field of the discharge gap, changing the working medium, forcing the flushing fluid, lifting the tool at regular intervals, etc. Liu, J. W. et al. used a high electrode rotation speed (EDM-HS). The experimental results of machining metal matrix composites with electrodes showed that the material removal rate was directly related to the rotational speed of the electrode, and the material removal rate increased with the increase of the electrode speed[8]. Yuhua Huang et al. investigated the effect of the rotational speed of the electrode on the machining efficiency. By comparing the experimental results, it was determined that the optimum electrode speed could effectively improve the machining efficiency[9]. M. Y. Tsai et al. investigated a vibration-assisted device for machining titanium alloy samples (Ti-6Al-4V) and found that machining a 10 mm deep groove with vibration-assisted EDM resulted in a 200% reduction in machining time compared to unassisted EDM[10].
Yerui Feng et al. proposed a high response frequency magnetic levitation spindle system (MSSS) EDM technique for high-precision micro-hole machining of zirconium diboride-silicon carbide (ZrB-SiC) ceramics and superalloy Inconel 718, and the experimental results showed that MSSSEDM has higher efficiency and quality compared with conventional EDM[11–12].
Dong Yinghuai et al. designed a small ultrasonic vibration-assisted EDM machine tool to avoid spark concentration and abnormal arcing during machining[13]. Liu Yu et al. investigated the effect of ultrasonic vibration tool electrodes on EDM machining efficiency, and the results showed that the periodic ultrasonic vibration promoted the movement of debris. The machining efficiency was improved compared with the conventional hole EDM[14]. Wenjun Kong et al. proposed a horizontal ultrasonic vibration EDM method to make up for the deficiencies of existing ultrasonic EDM technology. Comparative experimental results showed that machining efficiency, workpiece surface quality, and machining process were improved[15]. Wuyi Ming et al. conducted a study on magnetic field-assisted electrical discharge machining. The results of the study show that an appropriate magnetic field helps to improve energy utilization efficiency and material removal rate (MRR) at similar surface roughness. In particular, the MRR of magnetic materials (SKD11) showed a more significant improvement[16]. Preetkanwal Singh Bains et al. studied magnetic field-assisted EDM of metal matrix composites. The experimental results show that magnetic field-assisted EDM has significant process stability and can achieve high efficiency and quality EDM[17]. Gurpreet Singh et al. applied a combination of magnetic field and ultrasonic vibration to EDM and conducted a series of experiments, which showed that the combined effect of magnetic field and ultrasonic vibration on the machining area improved the machining efficiency of EDM[18]. Zhang Jin et al. proposed a high-speed EDM method combining Lorentz force, electric field force and high-speed electrode rotation, and the experimental results showed that the material removal rate was improved[19]. Chao Xu et al. atomized argon and oxygen as EDM media and compared the material removal during machining, and the experimental results showed that the discharge probability was improved and the machining efficiency was increased by more than 8 times[20]. Thrinadh Jadam et al. added multi-walled carbon nanotubes (MWCNT) at a concentration of 0.5 g/l to kerosene as a dielectric for EDM and conducted experiments by varying the peak discharge current. The experimental results show that the use of MWCNT hybrid dielectric can significantly improve the machining performance compared to conventional EDM[21]. Yi Jiang et al. used air and argon as gas media for EDM (Air-EDM and Ar-EDM, respectively) for the electrical discharge machining of TC4 titanium alloy and Cr12 steel. The experimental results show that the material removal rate of TC4 using Ar-EDM is almost four times higher than that using Air-EDM[22]. Reza Najati Ilkhchi et al. proposed a high-speed flushing system to flush the gap between the workpiece and the electrode and investigated the effect of the flushing system in the form of Reynolds number on the material removal rate. The experimental results showed that the efficiency of EDM increased by 44% as the Reynolds number increased[23]. Hao Ni et al. developed an EDM system that simultaneously uses pump forced flushing, ultrasonic vibration and electrode rotation to drill small deep holes. The results show that the combination of pump flushing with vibration and rotation can improve EDM efficiency[24]. Trias Andromeda et al. designed a PID controller based on a differential evolution algorithm to adjust the gap distance between the workpiece and the electrode in time to maintain the proper gap voltage. Simulation results verified the effectiveness of this controller[25]. Wang Jin et al. investigated the adaptive tool lifting technique, and the experimental results showed that the adaptive tool lifting technique can automatically adjust the tool lifting speed according to the discharge between electrodes. Therefore, the optimal machining parameters can guarantee the discharge machining in any machining. They determine the optimal electrode machining time by detecting the voltage and current signals between the electrodes and the workpiece and calculating the normal discharge frequency and abnormal discharge rate. Experimental results showed that the proposed strategy improved the efficiency of EDM[26].
To improve the positioning response speed of the electrode and the machining efficiency of the EDM, and to meet the requirements of high-speed and fine discharge machining. In this paper, a 5-DOF controllable magnetic levitation actuator is introduced. The actuator is compact and can be connected to a conventional EDM machine tool for EDM, enabling rapid positioning of the electrode and maintaining the proper distance between the workpiece and the electrode. Based on this, a local current feedback controller and decoupling control elements are used to reduce coupling interference and improve the response speed and positioning accuracy of the actuator as much as possible. Finally, the actuator was connected to a conventional EDM machine tool for micro-hole machining experiments, and the machining speed was evaluated. The possibility of creating machining is tried by controlling the movement of electrodes to machine complex-shaped workpieces.