Analysis of wall thickness variation of copper tube electrode processed by ultrasonic vibration

In this study, a new method of ultrasonic vibration processing of high-speed EDM ultra-fine copper tube electrode is proposed, and the deformation process of copper tube during processing is simulated by finite element analysis, and a prediction model of wall thickness change of ultrasonically processed copper tube electrode is established, and the predicted values are in good agreement with the experimental measurement data. The surface quality of copper tube electrode after ultrasonic processing was improved, and the roughness was reduced from Ra1.28 to Ra0.43 µm, which is important for the automated production of high-quality ultra-fine copper tube electrode.