Efficient Ti-6Al-4 V processing using submerged electric arc cutting with synergistically optimized parameters

To address persistent challenges of severe tool wear and poor surface integrity in Ti-6Al-4 V machining, this study pioneers an immersed rotating-disc electric arc cutting (EAC) system. this technology integrates synergistic control of pulse discharge parameters (voltage, duty cycle) and mechanical motions (electrode rotation, feed rate), establishing a new paradigm for efficient material removal in electric arc cutting. Establishing the first cross-material evaluation framework for EAC electrodes, we systematically quantified performance boundaries of four distinct materials (W70Cu30, graphite, Cu, 304 stainless steel) through multi-criteria metrics: material removal rate (MRR), surface roughness (Sa), relative electrode wear rate (REWR), and surface morphology. Employing Taguchi design (L16 orthogonal array) and ANOVA, we reveal critical interactions between electrical and mechanical parameters. Key findings: Voltage and feed rate dominantly control MRR. Electrode rotation critically mitigates arcing instability and surface defects. Optimized parameters (28 V, 900 rpm, 80% duty cycle, 40 mm/min) demonstrate Ti-6Al-4 V MRR exceeding 1500 mm3/min.