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<p>Multi-axis fast electrical discharge milling (MFED-milling) is an innovative machining method, yet its material removal mechanism and debris evacuation characteristics remain insufficiently investigated. Based on observational experimental results from our prior work, this study employed thermal-fluid coupling simulation to analyze the single-pulse discharge process and molten metal evolution under flow field action, and particle tracing simulation to investigate debris evacuation within the discharge gap during consecutive-pulse discharges. This dual-simulation approach elucidates the origins of high machining efficiency in MFED-milling from both the microscale perspective of material removal and macroscale perspective of machining stability. Thermal-fluid coupled analysis results show that the dominant material removal mechanism and its driving forces in MFED-milling are analogous to those in layered fast ED-milling (LFED-milling). The proportion of molten metal expelled from the molten pool is 37.3% of the total volume, lower than that in LFED-milling, indicating that high machining efficiency arises from a relatively high normal discharge rate. Particle tracing simulations reveal that internal flushing reduces residual debris to some extent, but debris accumulation increases with prolonged discharge. This demonstrates that sole reliance on internal flushing fails to maintain low residual debris levels in the gap during actual machining. Thus, supplementary flushing strategies or optimized machining parameters are necessary to mitigate debris accumulation and preserve a stable discharge environment, ensuring consistent high-efficiency machining performance in MFED-milling.</p>

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Numerical investigation into material removal mechanisms of multi-axis fast ED-milling

  • 期刊论文

  • 发表日期：

    2026年6月19日

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  • Jian Wang,
  • Lin Chen,
  • Lin-Jun Wu,
  • Lu-Gan,
  • Xiao-Lei Yu,
  • Ya-Ou Zhang,
  • Wan-Sheng Zhao

摘要

Multi-axis fast electrical discharge milling (MFED-milling) is an innovative machining method, yet its material removal mechanism and debris evacuation characteristics remain insufficiently investigated. Based on observational experimental results from our prior work, this study employed thermal-fluid coupling simulation to analyze the single-pulse discharge process and molten metal evolution under flow field action, and particle tracing simulation to investigate debris evacuation within the discharge gap during consecutive-pulse discharges. This dual-simulation approach elucidates the origins of high machining efficiency in MFED-milling from both the microscale perspective of material removal and macroscale perspective of machining stability. Thermal-fluid coupled analysis results show that the dominant material removal mechanism and its driving forces in MFED-milling are analogous to those in layered fast ED-milling (LFED-milling). The proportion of molten metal expelled from the molten pool is 37.3% of the total volume, lower than that in LFED-milling, indicating that high machining efficiency arises from a relatively high normal discharge rate. Particle tracing simulations reveal that internal flushing reduces residual debris to some extent, but debris accumulation increases with prolonged discharge. This demonstrates that sole reliance on internal flushing fails to maintain low residual debris levels in the gap during actual machining. Thus, supplementary flushing strategies or optimized machining parameters are necessary to mitigate debris accumulation and preserve a stable discharge environment, ensuring consistent high-efficiency machining performance in MFED-milling.