Multi-energy field simulation and experimental research on composite processing of long-narrow grooves assisted by a multiphase flow jet

Due to its excellent mechanical properties, thermal stability, and high-temperature fatigue resistance, nickel-based superalloy 718 is widely used in critical aircraft engine components. However, its extremely high mechanical strength and fatigue resistance present significant machining challenges. Wire electrical discharge machining (WEDM) enables processing various metal materials through pulse discharge, offering high efficiency and flexibility. However, WEDM induces thermal effects on the machined surface, potentially leading to undesirable outcomes. In contrast, wire electrochemical machining (WECM), a highly flexible, non-contact process, offers distinct advantages, including the absence of tool wear, cutting forces, and thermal effects. WECM can effectively mitigate the adverse effects of WEDM and facilitate further surface modifications. This study investigates the post-processing of large-area micro-scale groove arrays after WEDM using WECM assisted by a multiphase flow jet. It explored key machining parameters through simulations and validated the results through experiments. The findings demonstrated that WECM could effectively reduce the adverse effects of WEDM in a relatively short time, decreasing surface oxide content and roughness while enhancing the material's corrosion resistance.