Abstract Electrical discharge-assisted milling (EDAM) is proposed for difficult-to-cut metal materials. This machining method includes a milling operation and thermal assistance from electrical discharge machining (EDM). A special tool for EDAM was developed using two cemented carbide inserts and two copper electrodes. The inserts can easily cut the materials that are softened by the heat from EDM. The tool design was validated by analyzing the voltage signal, spark release process, and electrode wear during the machining process. Different energy levels were investigated for the electrical discharge assistance, including their effect on the morphological characteristics and composition of the modified layer. An experiment was carried out to compare EDAM and conventional milling using Ti-6Al-4V titanium alloy. The results show that EDAM can significantly reduce the tool wear and cutting force compared to conventional milling. The surface roughness was also greatly improved.

中文翻译：

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钛合金电火花辅助铣削加工

摘要 放电辅助铣削 (EDAM) 是针对难切削金属材料提出的。这种加工方法包括铣削操作和电火花加工 (EDM) 的热辅助。使用两个硬质合金刀片和两个铜电极开发了一种用于 EDAM 的特殊工具。刀片可以轻松切割因 EDM 产生的热量而软化的材料。通过分析加工过程中的电压信号、火花释放过程和电极磨损来验证刀具设计。研究了放电辅助的不同能级，包括它们对改性层的形态特征和组成的影响。进行了一项实验以比较 EDAM 和使用 Ti-6Al-4V 钛合金的常规铣削。结果表明，与传统铣削相比，EDAM 可以显着降低刀具磨损和切削力。表面粗糙度也大大提高。