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<p>TC4 titanium alloy is widely used in the aerospace field, but its high strength and easy passivation characteristics pose challenges to high-quality and high-efficiency machining. Electrolytic-assisted milling (EAM) combines mechanical cutting and anodic dissolution, which can effectively remove the passive film and improve machining stability. This study adopted the simulation modeling-pattern analysis-experimental verification methodology and established a multi-physics coupled simulation model to explore the effects of tool cathode fluid channel structure and machining parameters on the flow field, electric field, and chip flow. Verification results show that the narrow slit-shaped fluid channel provides the optimal flow uniformity and pressure distribution. Subsequently, the tool was designed and fabricated, and experimental research and process parameter optimization were carried out. Compared with traditional electrochemical machining, the optimized EAM process reduces the surface roughness by 70.4% and significantly improves the material removal rate. This study clarifies the synergistic material removal mechanism of EAM, providing a theoretical basis for the tool cathode design and process optimization of titanium alloy EAM.</p>

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Process optimization of electrolytic-assisted milling for titanium alloy based on numerical simulation and experimental study

  • 期刊论文

  • 发表日期：

    2026年5月4日

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  • Qi Wang,
  • Zhangyang Yin,
  • Yafeng He,
  • Sipeng Wang,
  • Xi Chen,
  • Chonghao Zhang

摘要

TC4 titanium alloy is widely used in the aerospace field, but its high strength and easy passivation characteristics pose challenges to high-quality and high-efficiency machining. Electrolytic-assisted milling (EAM) combines mechanical cutting and anodic dissolution, which can effectively remove the passive film and improve machining stability. This study adopted the simulation modeling-pattern analysis-experimental verification methodology and established a multi-physics coupled simulation model to explore the effects of tool cathode fluid channel structure and machining parameters on the flow field, electric field, and chip flow. Verification results show that the narrow slit-shaped fluid channel provides the optimal flow uniformity and pressure distribution. Subsequently, the tool was designed and fabricated, and experimental research and process parameter optimization were carried out. Compared with traditional electrochemical machining, the optimized EAM process reduces the surface roughness by 70.4% and significantly improves the material removal rate. This study clarifies the synergistic material removal mechanism of EAM, providing a theoretical basis for the tool cathode design and process optimization of titanium alloy EAM.