Flow Field Simulation and Experimental Study of Jet Electrolyte Plasma Micro-machining on TC4 Titanium Alloy

doi:10.3969/j.issn.1004-132X.2026.09.023

Abstract

Abstract:

A jet electrolyte plasma micro-machining（Jet-EPM） method was proposed. Using TC4 titanium alloy as the research subject， stationary jet machining experiments were first conducted to investigate the influence mechanism of machining time on the evolution of the machined morphology. Subsequently， moving jet micro-machining experiments were performed to analyze the influence of nozzle traverse speed and scan overlap ratio on the machined morphology. The results indicate that during the initial stage of stationary jet machining， material removal is concentrated in the central contact area of the jet. As machining time increases， the localization of material removal gradually decreases. In micro-groove machining， the machining quality improves with increasing nozzle traverse speed， but excessively high speeds cause excessive material removal at both ends of the path. During scanning machining， if the path overlap ratio is below 75%， wavy undulations perpendicular to the scanning direction appear on the workpiece surface.

Key words: electrolyte plasma, jet machining, TC4 titanium alloy, surface morphology, flow field

摘要：

提出了一种射流电解质等离子体微加工（Jet-EPM）方法。以TC4钛合金为研究对象，开展了定点射流加工实验，探究加工时间对加工形貌演化的影响机制。通过移动射流微加工实验，分析了喷嘴移动速度及扫描重叠率对加工形貌的影响规律。结果表明：定点射流加工初期，材料去除集中于射流接触中心区域；随着加工时间的延长，加工定域性逐渐降低。微槽加工中，加工质量随喷嘴移动速度提高而提升，但速度过高会导致路径两端材料过度去除。扫描加工时，若路径重叠率低于75%，工件表面将出现垂直于扫描方向的波纹状起伏。

关键词: 电解质等离子体, 射流加工, TC4钛合金, 表面形貌, 流场

CLC Number:

TG580

YI Jun, CHEN Hongfeng, MIAO Changchun, YIN Zeqing, DENG Hui. Flow Field Simulation and Experimental Study of Jet Electrolyte Plasma Micro-machining on TC4 Titanium Alloy[J]. China Mechanical Engineering, 2026, 37(9): 2305-2313.

易军, 陈洪峰, 苗长春, 尹泽清, 邓辉. TC4钛合金射流电解质等离子体微加工流场仿真与实验研究[J]. 中国机械工程, 2026, 37(9): 2305-2313.

Figures/Tables 16

Fig.1 Processing schematic

Fig.2 Experimental setup

Tab. 1 Experimental parameters for stationary jet machining

实验参数	数值
抛光液	1%（质量分数，下同）氟化钠+3%盐酸羟胺
抛光电压/V	300
温度/℃	85
时间t/s	15、30、45、60、90
喷嘴直径/mm	0.6
射流间隙/mm	8

Tab. 2 Experimental parameters for moving jet machining

实验参数	数值
抛光液	1%氟化钠+3%盐酸羟胺
抛光电压/V	300
温度/℃	85
时间t/s	30
喷嘴直径/mm	0.6
射流间隙/mm	8
移动速度v/（mm·s $- 1$ ）	10、20、30、40
重叠率/%	25、50、62.5

Tab. 2 Experimental parameters for moving jet machining

实验参数	数值
抛光液	1%氟化钠+3%盐酸羟胺
抛光电压/V	300
温度/℃	85
时间t/s	30
喷嘴直径/mm	0.6
射流间隙/mm	8
移动速度v/（mm·s $- 1$ ）	10、20、30、40
重叠率/%	25、50、62.5

Fig.3 Schematic diagram of the calculation of the average overcut

Fig.4 Schematic diagram of the simulation model

Fig.5 Pit morphology and current density distribution at different processing time

Fig.6 Physical images of pits under different processing time

Fig.7 Two-dimensional topography of pits under different processing time

Fig.8 Cross-sectional profiles of pits at different processing time

Fig.9 Average overcut at different processing time

Fig.10 Physical images of micro-grooves under different nozzle travel speeds

Fig.11 Distribution of groove width along the scanning direction

Fig.12 Cross-sectional profile at the middle of groove bottom along the scanning direction

Fig.13 Flow velocity and pressure distribution on micro-groove cross-section at different overlap rates

Fig.14 Three-dimensional morphology and cross-sectional profile of the micro-groove under different scanning overlap rates

References 18

[1]	BIFFI C A， FIOCCHI J， FERRARIO E， et al. Effects of the Scanning Strategy on the Microstructure and Mechanical Properties of a TiAl6V4 Alloy Produced by Electron Beam Additive Manufacturing［J］. The International Journal of Advanced Manufacturing Technology， 2020， 107（11）： 4913-4924.
[2]	王庆娟，杜旭东，蒋立，等. 退火处理对TC4钛合金航空发动机叶片组织与力学性能的影响［J］. 金属热处理， 2024， 49（10）： 126-132.
	WANG Qingjuan， DU Xudong， JIANG Li， et al. Effect of Annealing on Microstructure and Mechanical Properties of TC4 Titanium Alloy Aeroengine Blades［J］. Heat Treatment of Metals， 2024， 49（10）： 126-132.
[3]	许璐瑶，辛朝阳，王丽明. 航空内燃机用TB6钛合金高温压缩成形特性分析［J］. 锻压装备与制造技术， 2024， 59（4）： 144-146.
	XU Luyao， XIN Chaoyang， WANG Liming. High Temperature Compression Molding Characteristics of TB6 Titanium Alloy for Aviation Internal Combustion Engine［J］. China Metalforming Equipment & Manufacturing Technology， 2024， 59（4）： 144-146.
[4]	KE Xiaolong， WU Wei， WANG Chunjin， et al. Material Removal and Surface Integrity Analysis of Ti6Al4V Alloy after Polishing by Flexible Tools with Different Rigidity［J］. Materials， 2022， 15（5）： 1642.
[5]	BORDATCHEV E V， HAFIZ A M K， TUTUNEA-FATAN O R. Performance of Laser Polishing in Finishing of Metallic Surfaces［J］. The International Journal of Advanced Manufacturing Technology， 2014， 73（1）： 35-52.
[6]	BEZUIDENHOUT M， HAAR G T， BECKER T， et al. The Effect of HF-HNO₃ Chemical Polishing on the Surface Roughness and Fatigue Life of Laser Powder Bed Fusion Produced Ti6Al4V［J］. Materials Today Communications， 2020， 25： 101396.
[7]	QU Ningsong， FANG Xiaolong， ZHANG Junzhong， et al. Macro Electrochemical Milling and Its Hybrid Variants［J］. Chinese Journal of Aeronautics， 2024， 37（8）： 1-35.
[8]	MITCHELL-SMITH J， SPEIDEL A， CLARE A T. Advancing Electrochemical Jet Methods through Manipulation of the Angle of Address［J］. Journal of Materials Processing Technology， 2018， 255： 364-372.
[9]	GUO Cheng， QIAN Jun， REYNAERTS D. Deterministic Removal Strategy for Machine Vision Assisted Scanning Micro Electrochemical Flow Cell［J］. Journal of Manufacturing Processes， 2018， 34： 167-178.
[10]	YU Mingxin， DU Liqun， WANG Fenglai， et al. A New Laser-induced Plasma Electrolyte Jet Machining Method： Efficient Material Removal Mechanism and Synergistic Effects［J］. Journal of Materials Processing Technology， 2024， 326： 118319.
[11]	WANG Ji， SUO Laichun， GUAN Lili， et al. Analytical Study on Mechanism of Electrolysis and Plasma Polishing［J］. Advanced Materials Research， 2012， 472/473/474/475： 350-353.
[12]	陈扬建，易军，王宗伟，等. 电解质等离子体抛光的多物理场耦合仿真及实验研究［J］. 机械工程学报， 2025， 61（1）： 360-370.
	CHEN Yangjian， YI Jun， WANG Zongwei， et al. Multi-physical Field Coupling Simulation and Experimental Research on Electrolyte Plasma Polishing［J］. Journal of Mechanical Engineering， 2025， 61（1）： 360-370.
[13]	邹永纯，王树棋，陈国梁，等. 304钢等离子体电解抛光工艺与其表面结构性能研究［J］. 表面技术， 2023， 52（6）： 51-60.
	ZOU Yongchun， WANG Shuqi， CHEN Guoliang， et al. Process， Surface Structure and Properties of 304 Steel by Plasma Electrolytic Polishing［J］. Surface Technology， 2023， 52（6）： 51-60.
[14]	QUITZKE S， KRÖNING O， SAFRANCHIK D， et al. Design and Setup of a Jet-based Technology for Localized Small Scale Plasma Electrolytic Polishing［J］. Journal of Manufacturing Processes， 2022， 75： 1123-1133.
[15]	KRANHOLD C， KRÖNING O， SCHULZE H P， et al. Investigation of Stable Boundary Conditions for the Jet-electrolytic Plasma Polishing （Jet-ePP）［J］. Procedia CIRP， 2020， 95： 987-992.
[16]	KAI S， KUNIEDA M. Study on Effect of Assist Gas in Electrolyte Jet Machining［J］. Journal of the Japan Society of Electrical Machining Engineers， 2013， 47（115）： 97-103.
[17]	JAIN V K， LAL G K， KANETKAR Y. Stray Current Attack and Stagnation Zones in Electrochemical Drilling［J］. The International Journal of Advanced Manufacturing Technology， 2005， 26（5/6）： 527-536.
[18]	王玉峰，杨勇，刘云峰，等. 大深径比小孔激光与管电极电解同步复合加工技术［J］. 航空制造技术， 2025， 68（1）： 64-72.
	WANG Yufeng， YANG Yong， LIU Yunfeng， et al. Fabrication of High-aspect-ratio Small Holes by Laser and Shaped Tube Electrochemical Machining［J］. Aeronautical Manufacturing Technology， 2025， 68（1）： 64-72.