Abstract:In this paper, a novel micro plastic forming technology is introduced for the forming of micro-gear using the high strength, toughness, and hard-to-deform Ti6Al4V alloy material. The experimental results showed that the Ti6Al4V alloy micro-gear can be achieved successfully from a cylindrical Ti6Al4V billet with a set of graphite die under an electric field. The Ti6Al4V material exhibits the best formability when the heating rate is 5 ℃/s, however, higher heating rate 30 ℃/s and 40 ℃/s can effectively shorten the time for pre-heating the material for deformation. The microstructure in all the formed samples have the Widmanst?tten structure. but gear center in contradiction to tooth top which exhibit a finer microstructure, and the β phase content of specimens with the heating rates of 5 ℃/s and 10 ℃/s are slightly higher than the original billet but specimens involving in heating rates 20 ℃/s, 30 ℃/s, and 40 ℃/s show nothing of the β phase from XRD analysis. Moreover, Vickers hardness of all formed samples increase than that of the original billet after an electric field, and which is independent on the heating rates.