Abstract
In order to improve the surface forming quality and machining efficiency of composite materials and reduce tool wear, a two-dimensional rotary ultrasonic combined electro-machining (2DRUEM) technology with low electrical conductivity and low current density was proposed in this study. Additionally, a gap detection unit of the machining system was designed with the integration of grinding force and gap current, and the average errors and maximum errors of the model were 5.61% and 12.08%, respectively, which were better than single detection. Furthermore, the machining parameters were optimally selected via NSGA-II, and the maximum machining surface roughness error was 5.9%, the maximum material removal rate error was 5.5%, and the maximum edge accuracy error was 8.9%, as established through experiments.