Abstract: The synchronous mode between ultrasonic vibrations and micro electrical machining power is analyzed and explored. The power chopper is designed and made, based on the ultrasonic vibration parameters detected by the high-speed micro-displacement laser sensor, the chopper pulses are given, which may turn on and turn off the micro electrical machining power, so that orderly synchronization can be fulfilled between the micro electrical machining power and the ultrasonic vibration in real-time way, and the electrical machining system is improved. Using high-frequency pulse voltage that amplitude is less than 6 V, the low conductivity passivation electrolyte, the mechanism tests are carried, by comparing the test results of a few machining ways, such as the single ultrasonic machining, the ultrasonic direct current, the ultrasonic electrolysis and ultrasonic pulse synchronization electrochemical machining, the technical advantages of synchronous ultrasonic machining mode are verified, which can improve the machining accuracy and the surface quality. Using the compound alcohol working fluid mixed micro-powder with semiconductivity, by the synchronous ultrasonic modulation, the ultrasonic combined electro-discharged & electrolytic machining can be fulfilled, the stability and productivity may be improved, at the same time to ensure the accuracy and the surface quality.

Key words: ultrasonic vibration;synchronization;pulse chopper;electro-discharged & electrolysis;micro-machining