The present work analyzes the energy channelization behavior during the triplex hybrid process of ultrasonic assisted electrochemical discharge machining (UA-ECDM). In this work, a high frequency (35 kHz) low amplitude configuration of ultrasonic vibrations has been employed to investigate the ECDM process. The underlying energy channelization mechanism during the UA-ECDM process has been demonstrated while considering the evidence from high-speed imaging of gas film, discharge signals, optical images, simulation results, structural and compositional analysis of machined work material. The controlled assistance of ultrasonic in the ECDM process shifts the energy paradigm from the edges to the center of the tool electrode. Moreover, in the UA-ECDM process, the material is removed by additional cavitation and high-pressure evacuation actions along with melting, vaporization, and chemical etching phenomenon. An improved frequency of spark discharges indicates the initiation of breakdown phenomena in upward and downward strokes of ultrasonic vibrations. Energy channelization index and specific energy were taken as the performance indicators. The incorporation of ultrasonic vibrations consumed 2.23 times less energy than the ECDM process to remove a unit material per unit time. The energy channelization index with ultrasonic assistance is also improved by five times. The incorporation of ultrasonic vibrations in the ECDM process reduced the heat-affected zone and produced the machined surfaces without the alkali deficient layer. The article reports the parametric effect and their contribution to the response characteristics. The involvement of high electrochemical discharge energy with ultrasonic assistance exhibits better results in higher material removal rate and depth/diameter ratio due to the parallel provision for the evacuation of sludge/debris and electrolyte replenishment in the machining zone.

本工作分析了超声辅助电化学放电加工（UA-ECDM）的三重混合过程中的能量通道化行为。在这项工作中，超声振动的高频（35 kHz）低振幅配置已被用于研究ECDM工艺。在考虑了气膜高速成像，放电信号，光学图像，模拟结果，机械加工材料的结构和成分分析的证据后，已经证明了UA-ECDM过程中潜在的能量通道化机制。ECDM过程中超声的受控辅助将能量范式从工具电极的边缘转移到中心。此外，在UA-ECDM流程中，通过额外的气蚀和高压抽空动作以及熔化，汽化和化学蚀刻现象，可以去除材料。火花放电频率的提高表明在超声振动的向上和向下冲程中出现了击穿现象。能量通道化指数和比能为性能指标。超声振动的合并所消耗的能量比每单位时间除去单位材料的ECDM工艺要少2.23倍。超声辅助下的能量通道化指数也提高了五倍。ECDM工艺中引入的超声波振动减少了热影响区并产生了没有碱缺乏层的机加工表面。本文报告了参数效应及其对响应特性的贡献。高电化学放电能量与超声辅助的结合表现出更好的材料去除率和深度/直径比的更好结果，这是因为在加工区中可以同时排空污泥/碎屑和补充电解液。