Tool wear inevitably occurs during electrical discharge milling (ED milling), adversely affecting the form precision of machined features. Specifically, radial tool wear negatively influences copying precision. In this study, electrical discharge ablation milling (EDA milling) with a microcutting depth was investigated to improve the machining precision of discharge milling. In the proposed method, the cutting depth of a single layer was kept at the micron level, which is smaller than the discharge gap, and the electrode was set to a fast feeding rate at a constant speed. The microcutting depth of a single layer made the discharge concentrate at the end of the electrode while avoiding the side. Under this method, radial tool wear is prevented to realize high-precision discharge milling. The discharge state and high-precision mechanism of the proposed method were analyzed. Contrast experiments were conducted to compare conventional electrical discharge milling (ED milling), conventional electrical discharge ablation milling with a large cutting depth (EDA milling with a large cutting depth), and EDA milling with a microcutting depth. Results indicated that when peak current was 30A (pulse duration was 150 μs and pulse interval was 120 μs), the machining efficiency of the proposed method (18.8 mm³/min) was 9.5 times that of ED milling (1.97 mm³/min) and was 62% higher than that of EDA milling with a large cutting depth (11.6 mm³/min). Besides, the surface quality and cross-sectional shape precision of the straight groove were significantly improved compared with EDA milling with a large cutting depth.

在电火花铣削（ED铣削）中不可避免地会发生刀具磨损，从而不利地影响加工特征的形状精度。具体地说，径向工具的磨损会对复印精度产生负面影响。在这项研究中，对具有微切削深度的电火花烧蚀铣削（EDA铣削）进行了研究，以提高放电铣削的加工精度。在所提出的方法中，将单层的切割深度保持在微米水平，该水平小于放电间隙，并且将电极设置为恒定速度的快速进给速度。单层的微切割深度使放电集中在电极的端部，同时避开了侧面。通过这种方法，可以防止径向刀具磨损，从而实现高精度的放电铣削。分析了该方法的放电状态和高精度机理。进行对比实验以比较常规的电火花铣削（ED铣削），具有大切削深度的常规电火花烧蚀铣削（具有大切削深度的EDA铣削）和具有微切削深度的EDA铣削。结果表明，当峰值电流为30A（脉冲持续时间为150μs，脉冲间隔为120μs）时，该方法的加工效率为18.8 mm³ / min）是ED铣削（1.97 mm ³ / min）的9.5倍，比具有大切削深度（11.6 mm ³ / min）的EDA铣削高出62％。此外，与大切削深度的EDA铣削相比，直槽的表面质量和横截面形状精度显着提高。