This paper develops a novel processing method of plasma electrolytic oxidation-assisted micromilling (PEOAM). Electrolyte solutions with KH₂PO₄, NaAlO₂, or Na₂SiO₃ as the main component are designed, and three types of oxide films are grown on the surface of a Ti6Al4V alloy in situ by means of plasma electrolytic oxidation. The morphology and composition of the oxide films are characterized by scanning electron microscope and energy dispersive spectrum. Additionally, the cutting force and surface roughness of PEOAM are measured by dynamometer and white light interferometer, respectively. A comparison between PEOAM and conventional micromilling in terms of cutting force, tool wear, chips, and surface roughness is conducted, with results showing that oxide films with about 20 μm thickness are loose and porous, their hardness decreasing to a minimum of 1.12 GPa, which corresponds to 23.3% of the original hardness value. At the axial cutting depth of 18 μm, compared to the F_x, F_y , and F_z values of the Ti6Al4V alloy substrate, the average milling forces of the NaAlO₂ oxide film are the most significantly reduced (35.1%, 15.7%, and 94.8% of the original values, respectively). At the axial cutting depth of 25 μm, the surface roughness (R _a) value of PEOAM is reduced by 0.08–0.12 μm. Consequently, under the same cutting parameters, PEOAM can effectively reduce the cutting force, prolong the service life of the tool, and improve surface quality.

本文开发了一种新型的等离子体电解氧化辅助微铣削（PEOAM）加工方法。设计了以KH ₂ PO ₄，NaAlO ₂或Na ₂ SiO ₃为主要成分的电解质溶液，并在Ti6Al4V合金表面原位生长了三种氧化膜通过等离子电解氧化。氧化膜的形貌和组成由扫描电子显微镜和能量色散谱表征。另外，PEOAM的切削力和表面粗糙度分别通过测力计和白光干涉仪测量。在切削力，刀具磨损，芯片，和表面粗糙度方面PEOAM和常规微研磨之间的比较进行，结果显示，氧化膜用约20 μ米厚度是松散和多孔的，它们的硬度降低到最小1.12吉帕，相当于原始硬度值的23.3％。在18的轴向切削深度μ米，相比˚F _X，F _ÿ ，和˚F Ti6Al4V合金基材的_z值，NaAlO ₂氧化膜的平均铣削力降低幅度最大（分别为原始值的35.1％，15.7％和94.8％）。在25轴向切削深度μ米，表面粗糙度（ ř _一个）PEOAM的值是通过减少0.08-0.12 μ米。因此，在相同的切削参数下，PEOAM可以有效降低切削力，延长工具的使用寿命，并改善表面质量。