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<p>Conventional wire electrical discharge machining (wire EDM) produces a molten and resolidified surface layer (recast layer) with a certain thickness on workpiece machined surfaces, which is unacceptable for key components in aerospace and gas turbine applications. Electrochemical machining (ECM) offers distinct advantages in achieving superior surface quality. Accordingly, the hybrid integration of EDM and ECM represents a highly effective approach to high-precision, high-quality wire cutting. To eliminate the residual recast layer formed on workpiece surfaces during conventional wire EDM, this study proposes a novel combined wire EDM-ECM machining process based on a reciprocating wire EDM machine. In the wire EDM ECM combining processes, the workpiece was firstly contoured to the target geometry via wire EDM with deionized water as the working medium. Subsequently, the machined surface of the wire-EDM-processed workpiece was polished by wire ECM using sodium chloride (NaCl) electrolyte. In this investigation, key processing parameters, including the motion mode of the molybdenum wire, wire offset, electrolyte conductivity, open-circuit voltage, electrolytic current, wire feeding speed, duty cycle and pulse width, were systematically investigated. Through the optimization of processing parameters, recast-layer-free machining and mirror surface finishing of 738 nickel-based superalloy were successfully realized in this study, with the surface roughness parameters controlled at Sa ≤ 0.1202&#xa0;μm and Ra ≤ 0.1090&#xa0;μm. The proposed hybrid method possesses promising application prospects for high-precision and high-quality wire cutting of difficult-to-machine materials in the aerospace industry.</p>

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Mirror surface machining by wire EDM ECM combining processes

  • 期刊论文

  • 发表日期：

    2026年7月1日

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  • Fan Chen,
  • JiaXuan Han,
  • Jing Liu,
  • Xiang Chen,
  • Xiaoming Yue

摘要

Conventional wire electrical discharge machining (wire EDM) produces a molten and resolidified surface layer (recast layer) with a certain thickness on workpiece machined surfaces, which is unacceptable for key components in aerospace and gas turbine applications. Electrochemical machining (ECM) offers distinct advantages in achieving superior surface quality. Accordingly, the hybrid integration of EDM and ECM represents a highly effective approach to high-precision, high-quality wire cutting. To eliminate the residual recast layer formed on workpiece surfaces during conventional wire EDM, this study proposes a novel combined wire EDM-ECM machining process based on a reciprocating wire EDM machine. In the wire EDM ECM combining processes, the workpiece was firstly contoured to the target geometry via wire EDM with deionized water as the working medium. Subsequently, the machined surface of the wire-EDM-processed workpiece was polished by wire ECM using sodium chloride (NaCl) electrolyte. In this investigation, key processing parameters, including the motion mode of the molybdenum wire, wire offset, electrolyte conductivity, open-circuit voltage, electrolytic current, wire feeding speed, duty cycle and pulse width, were systematically investigated. Through the optimization of processing parameters, recast-layer-free machining and mirror surface finishing of 738 nickel-based superalloy were successfully realized in this study, with the surface roughness parameters controlled at Sa ≤ 0.1202 μm and Ra ≤ 0.1090 μm. The proposed hybrid method possesses promising application prospects for high-precision and high-quality wire cutting of difficult-to-machine materials in the aerospace industry.