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<p>Improper parameters during WEDM processing of titanium alloys can cause surface color changes and affect material removal rate (MRR) and surface roughness (<i>R</i><sub>a</sub>). By using the principle of thin film interference color development, it was found that TI-6AL-4V undergoes surface oxidation and forms a layer of titanium oxide film under the influence of high temperature between electrodes and electrolysis during the processing, resulting in different visual colors. This article conducts process parameter optimization experiments through the design of L<sub>16</sub> (4<sup>4</sup>) orthogonal experimental method. The main optimization indicators are titanium oxide film thickness (Ox), MRR, and <i>R</i><sub>a</sub>, and the process parameters are the number of power tubes (PTs), pulse width (Ton), pulse gap (Toff), and tracking parameters (TPs). Using the signal-to-noise ratio analysis method, the influence of various process parameters on different optimization indicators and the optimal combination of single objective processing parameters were studied and experimentally verified. The results indicate that the minimum Ox can be obtained when Ton is 12, Toff is 8, PT is 4, and TP is 2. When Ton is 3, Toff is 2, PT is 1, and TP is 150, the minimum R<sub>a</sub> can be obtained. When Ton is 9, Toff is 2, PT is 2, and TP is 2, the maximum MRR can be obtained.</p>

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Research on Surface Coloring Mechanism and Parameter Optimization of Titanium Alloy in Wire Electrical Discharge Machining

  • 期刊论文

  • 发表日期：

    2025年8月12日

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  • Kaimin Xiao,
  • Linglei Kong,
  • Zhidong Liu,
  • Weining Lei,
  • Xudong Zhang

摘要

Improper parameters during WEDM processing of titanium alloys can cause surface color changes and affect material removal rate (MRR) and surface roughness (Ra). By using the principle of thin film interference color development, it was found that TI-6AL-4V undergoes surface oxidation and forms a layer of titanium oxide film under the influence of high temperature between electrodes and electrolysis during the processing, resulting in different visual colors. This article conducts process parameter optimization experiments through the design of L16 (44) orthogonal experimental method. The main optimization indicators are titanium oxide film thickness (Ox), MRR, and Ra, and the process parameters are the number of power tubes (PTs), pulse width (Ton), pulse gap (Toff), and tracking parameters (TPs). Using the signal-to-noise ratio analysis method, the influence of various process parameters on different optimization indicators and the optimal combination of single objective processing parameters were studied and experimentally verified. The results indicate that the minimum Ox can be obtained when Ton is 12, Toff is 8, PT is 4, and TP is 2. When Ton is 3, Toff is 2, PT is 1, and TP is 150, the minimum Ra can be obtained. When Ton is 9, Toff is 2, PT is 2, and TP is 2, the maximum MRR can be obtained.