1. General information
Project Title: Research on Ultrasonic Vibration-Assisted Electrical Discharge Machining of External Cylindrical Surfaces Using Graphite Electrodes
Project Code: B2024-TNA-18
Project Leader: Prof. Dr. Vu Ngoc Pi
Host Institution: Thai Nguyen University
Duration: 2024–2025
2. Objective(s)
- To establish a theoretical framework and comprehensive overview of electrical discharge machining (EDM) assisted by ultrasonic vibration.
- To design and fabricate an ultrasonic vibration head suitable (or optimal) for EDM of external cylindrical surfaces using graphite electrodes.
- To determine the reasonable (or optimal) parameter values for the ultrasonic vibrationassisted EDM process of external cylindrical surfaces with graphite electrodes.
- To design a technological process for manufacturing shaped tablet-punch tools assisted
by ultrasonic vibration.
3. Research results
- The material removal rate (MRR) increased by 36.31%.
- The surface roughness (Ra) increased from 3.15 µm to 3.91 µm, yet it remained within the acceptable limit (Ra < 4 µm) for many precision mechanical applications when using the AHP-based UV-EDM approach.
4. Products
4.1. Publications
1. V.-T. Dinh, T.-Q. Le, D.-B. Vu, N.-P. Vu, and T.-L. Mai, "Ultrasonic EDM for External Cylindrical Surface Machining with Graphite Electrodes: Horn Design and Hybrid NSGA II–AHP Optimization of MRR and Ra," Machines, vol. 13, no. 8, p. 675, 2025. (ranking: Q2, SCIE)
2. Huu Danh Tran, Hoang Anh Le, Cong Danh Nguyen, Van Thanh Dinh, Tat Loi Mai,
Manh Cuong Nguyen*, A Decision-Supporting Multi-Objective Approach for VibrationAssisted EDM of HARDOX 500 Using NSGA-II and AHP, Engineering, Technology& Applied Science Research (ETASR), Vol. 15, No. 6, 2025, 29354-29361, E-ISSN: 1792- 8036 (ranking: Q2, Scopus). (Accepted)
3. Trần Hữu Danh, Mai Tất Lợi, Vũ Ngọc Pi, và Nguyễn Mạnh Cường*, Tối ưu hóa đa mục tiêu và ra quyết định trong quá trình gia công xung điện thép HARDOX 500 có trợ giúp rung siêu âm sử dụng thuật toán NSGA-II kết hợp với các phương pháp SAW, MARCOS VÀ TOPSIS, Tạp chí Cơ khí Việt Nam, Số 333, tháng 10 năm 2025, Trang 34-42.
4. Trần Hữu Danh, Nguyễn Công Danh, Mai Tất Lợi, Vũ Ngọc Pi, và Nguyễn Mạnh Cường*, Tối ưu hóa đồng thời năng suất bóc tách vật liệu và độ nhám bề mặt trong gia công tia lửa điện có hỗ trợ rung động siêu âm trên thép HARDOX 500 bằng phương pháp NSGA-II VÀ MABAC, Tạp chí Cơ khí Việt Nam, Số 334, tháng 11 năm 2025 (Accepted).
4.2. Training Products
- 03 doctoral research topics
- 01 master’s thesis
4.3. Application Products
- One design package of an ultrasonic vibration head and the corresponding reasonable (or optimal) discharge parameters for EDM using graphite electrodes with ultrasonic assistance, applied to the machining of shaped tablet punches with diameters from 6 - 18 mm made of alloy tool steel;
5. Effectiveness
5.1. For education and training
- The research project establishes a meaningful connection between theoretical studies on advanced machining methods (EDM) and their practical applications in industrial manufacturing.
- Conducting this study contributes to enhancing the research capacity of the project members and serves as a driving force for developing the Mechanical Machining Optimization research group at Thai Nguyen University.
- The project provides PhD candidates and graduate students with an applied research and experimental model of technological equipment and workpieces related to the study, thereby contributing to postgraduate (master’s and doctoral) training.
5.2. In related fields of science and technology
- The research outcomes contribute to improving technological processes, increasing productivity, and enhancing the machining quality of shaped tablet punches.
- The findings also provide a scientific and technical foundation for further studies aimed at improving the efficiency and surface quality of the EDM process.
5.3. For socio-economic development
- The application of the project’s results is expected to increase productivity and product quality in the manufacture of shaped punch and die components.
- The outcomes support the modernization of industrial production and help reduce dependence on highly skilled manual labor.
- The results will also assist in improving manufacturing processes, enhancing product quality, and strengthening the competitiveness of commercial manufacturing enterprises.
5.4. For the host organization and cooperating institutions For the Host Institution (Thai Nguyen University):
- Creates opportunities for professional development among in-house scientists;
- Strengthens cooperation in scientific research and technology transfer;
- Promotes the commercialization of research outputs, contributing to the reputation and
brand development of Thai Nguyen University.
For the Partner Institution (Thai Ha Precision Mechanical Private Enterprise):
- Strengthens collaboration in research and technology transfer;
- Gains access to research results for continued product development and
commercialization;
- Engages in technology transfer activities and production of advanced technological equipment.
6. Application Potential
The research outcomes have been transferred to Thai Ha Precision Mechanical Private Enterprise for continued development and commercialization of the resulting technology and products
