Abstract
A method using mixed gas atomization discharge ablation milling (MA-DAM) for machining titanium alloys was proposed to address the processing efficiency and quality issues in conventional near-dry electrical discharge milling (N-EDM). By analyzing the discharge waveform, a pulse discharge physical model was established to reveal the machining mechanisms of N-EDM and MA-DAM. It was found that the latter had a unique ablation process compared to the former, resulting in better machining performance. The results of oxygen concentration experiments showed that compared to N-EDM, MA-DAM improved the material removal rate by 55.6 % and reduced the relative electrode wear rate by 50 %, but increased the width of the overcut by approximately 10 % and the average roughness by approximately 17 %. Orthogonal experiments and variance analysis were conducted to study the effects of the current, duty cycle, gas pressure, and atomization rate on the machining performance indicators. Finally, grey relational analysis was used for the multi-objective optimization of machining parameters to obtain the optimal process configuration for MA-DAM, which was validated through experiments.
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