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<p>To address the low efficiency and severe wear associated with traditional rod electrodes in the low-voltage micro-arc machining (LVMM) of Ti6Al4V titanium alloy, a novel machining scheme employing graphite disc electrodes was proposed. Comparative experiments between disc and rod electrodes were conducted to evaluate the machining performance of disc electrodes, and the effects of voltage and feed rate on machining outcomes were systematically explored. Material removal rate (MRR), relative tool wear rate (RTWR), workpiece surface morphology, and heat-affected zone (HAZ) characteristics were analyzed via scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and metallographic techniques. The results indicated that the maximum MRR of the disc electrodes reached 1805.14&#xa0;mm³/min, representing a 79.53% improvement over that of rod electrodes, while the minimum RTWR decreased to 0.23% (a reduction of 30.3%). The disc electrode sustained machining at a feed rate of 30&#xa0;mm/min under 22&#xa0;V, whereas the rod electrode fractured under the same conditions. As the voltage increased, the MRR increased significantly, and the RTWR decreased; however, both the workpiece surface roughness (Sa) and HAZ thickness increased. As the feed rate increased, the MRR improved, the RTWR exhibited a nonlinear trend (initially increasing and then decreasing), and the HAZ thickness initially decreased and then increased. Energy dispersive spectroscopy analysis revealed a significant increase in carbon and oxygen content on the machined surface, owing to graphite electrode wear and oxidation reactions between the workpiece and ambient air. Overall, the proposed LVMM method using disc electrodes effectively overcame the machining limitations of Ti6Al4V and provided both experimental as well as theoretical support for high-efficiency, low-wear machining of difficult-to-machine materials.</p>

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Research on a novel low-voltage micro-arc electrode milling process for Ti6Al4V

  • 期刊论文

  • 发表日期：

    2026年5月8日

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  • Guoyu Lian,
  • Ziteng Lu,
  • Jiayang Huang,
  • Qiaoru Niu,
  • Weikang Yang,
  • Jianping Zhou,
  • Yan Xu,
  • Jianping Zhou,
  • Yan Xu

摘要

To address the low efficiency and severe wear associated with traditional rod electrodes in the low-voltage micro-arc machining (LVMM) of Ti6Al4V titanium alloy, a novel machining scheme employing graphite disc electrodes was proposed. Comparative experiments between disc and rod electrodes were conducted to evaluate the machining performance of disc electrodes, and the effects of voltage and feed rate on machining outcomes were systematically explored. Material removal rate (MRR), relative tool wear rate (RTWR), workpiece surface morphology, and heat-affected zone (HAZ) characteristics were analyzed via scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and metallographic techniques. The results indicated that the maximum MRR of the disc electrodes reached 1805.14 mm³/min, representing a 79.53% improvement over that of rod electrodes, while the minimum RTWR decreased to 0.23% (a reduction of 30.3%). The disc electrode sustained machining at a feed rate of 30 mm/min under 22 V, whereas the rod electrode fractured under the same conditions. As the voltage increased, the MRR increased significantly, and the RTWR decreased; however, both the workpiece surface roughness (Sa) and HAZ thickness increased. As the feed rate increased, the MRR improved, the RTWR exhibited a nonlinear trend (initially increasing and then decreasing), and the HAZ thickness initially decreased and then increased. Energy dispersive spectroscopy analysis revealed a significant increase in carbon and oxygen content on the machined surface, owing to graphite electrode wear and oxidation reactions between the workpiece and ambient air. Overall, the proposed LVMM method using disc electrodes effectively overcame the machining limitations of Ti6Al4V and provided both experimental as well as theoretical support for high-efficiency, low-wear machining of difficult-to-machine materials.