Titanium alloy (Ti-6Al-4V) is a difficult-to-machine material, known for its excellent physical and chemical properties. However, traditional machining methods incur high tool wear costs when processing this material. The near-dry electrical discharge milling (N-EDM) method, which removes excess material via electroerosion, mitigates the impact of titanium alloy's hardness and strength, enabling effective material cutting. To enhance machining efficiency and surface quality, this study employs a simulation model of the inter-electrode flow field, combined with experimental data, to investigate the effect of milling thickness on key machining parameters and determine the optimal thickness. Subsequently, a four-factor, three-level (L