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<p>To address the challenge of debris removal in sidewall electrical discharge milling machining of Ti6Al4V, this study proposes an immersed short electric arc machining method. By immersing the workpiece and edged tool electrode in dielectric fluid, dielectric flow is induced through electrode rotation, thereby replacing the conventional dielectric jet. Simulation and experimental results demonstrate that the edged tool electrode significantly enhances debris removal efficiency through the formation of a vortex flow field in the immersed dielectric environment condition. The immersed condition reduces the relative electrode wear rate by 60.24%, while the 3D surface roughness is reduced by 17.5% with the edged tool electrode compared to the cylinder one. Moreover, the immersed condition decreases the average permutation entropy of discharge waveforms, indicating improved machining stability. When integrated with high power input voltage and high feed rate, the proposed approach achieves a lower input specific energy consumption. Notably, this technique eliminates the need for an external jet, thereby reducing equipment complexity and electrode cost. It also prevents the generation of metal aerosols and mitigates arc noise and light pollution.</p>

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Vortex-induced debris removal in immersed short electric arc machining of Ti6Al4V: a jet-free sidewall EDM milling approach

  • 期刊论文

  • 发表日期：

    2026年5月1日

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  • Liu Bin,
  • Zhou Jianping,
  • Song Jie,
  • Huang Jiayang,
  • Liu Kai,
  • Wang Bo,
  • Xu Yan,
  • Gui Xiancheng

摘要

To address the challenge of debris removal in sidewall electrical discharge milling machining of Ti6Al4V, this study proposes an immersed short electric arc machining method. By immersing the workpiece and edged tool electrode in dielectric fluid, dielectric flow is induced through electrode rotation, thereby replacing the conventional dielectric jet. Simulation and experimental results demonstrate that the edged tool electrode significantly enhances debris removal efficiency through the formation of a vortex flow field in the immersed dielectric environment condition. The immersed condition reduces the relative electrode wear rate by 60.24%, while the 3D surface roughness is reduced by 17.5% with the edged tool electrode compared to the cylinder one. Moreover, the immersed condition decreases the average permutation entropy of discharge waveforms, indicating improved machining stability. When integrated with high power input voltage and high feed rate, the proposed approach achieves a lower input specific energy consumption. Notably, this technique eliminates the need for an external jet, thereby reducing equipment complexity and electrode cost. It also prevents the generation of metal aerosols and mitigates arc noise and light pollution.