Investigation of chatter influencing factors in low-voltage weak arc milling of Ti-6Al-4V thin-walled structures

This study investigates the thin-walled titanium alloy Ti-6Al-4V (TC4) as the research object, aiming to elucidate the primary factors influencing chatter during pure low-voltage weak arc machining. By employing single-factor experiments, mathematical models were established to quantify the relationships between key process parameters and chatter characteristics. The findings unveil a clear mathematical association between chatter behavior and surface morphology under non-mechanical friction-induced chatter conditions. The results demonstrate a significant linear correlation between chatter characteristic values and the resultant surface morphology of the workpiece. Among the investigated process parameters, discharge frequency and side milling thickness emerged as the most influential factors affecting chatter. In the specific context of pure low-voltage weak arc machining, chatter exclusively induces adverse effects. Consequently, it is recommended that the thickness of each milling pass and the discharge frequency be minimized during practical machining operations to effectively mitigate the detrimental impacts of chatter.