Abstract This study proposes a combined method for the electrochemical mill-grinding of Ti–6Al–4V alloy to achieve a high material removal rate, high machining accuracy and good surface quality based on rough and finish machining. In the rough machining stage, a maximum feed rate of 2.7 mm min−1 and a material removal rate of 248.3 mm3 min−1 were achieved experimentally at a 10 mm cut depth using an abrasive tool with five rows of tool-sidewall outlet holes. In the finish machining stage, there were almost no overcuts or stray corrosions produced. The sidewall surface roughness and sidewall flatness were Ra = 1.06 and 76.8 μm after the finishing stage, which represent a 68% and 79.2% improvement compared with the rough machining stage, respectively. Finally, we fabricated a 1-mm-thick thin-walled structure using the combined machining operations, in which approximately 96% of the total material removal volume was performed at the rough machining stage.

中文翻译：

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Ti-6Al-4V合金的电化学铣磨复合粗精加工

摘要 本研究提出了一种基于粗精加工的Ti-6Al-4V合金电化学铣磨复合方法，以实现高材料去除率、高加工精度和良好的表面质量。在粗加工阶段，使用带有五排工具侧壁出口孔的磨具，在 10 mm 的切削深度下，通过实验实现了 2.7 mm min-1 的最大进给率和 248.3 mm3 min-1 的材料去除率。在精加工阶段，几乎没有产生过切或杂散腐蚀。精加工阶段后侧壁表面粗糙度和侧壁平坦度分别为 Ra = 1.06 和 76.8 μm，与粗加工阶段相比，分别提高了 68% 和 79.2%。最后，我们使用组合加工操作制造了 1 毫米厚的薄壁结构，