The present study aims to precisely manufacture the turbine wheel slot using a novel trim-offset approach of wire-electrical-discharge-machining (WEDM) in order to overcome the challenges of a conventional broaching process. Two dimensional model of turbine wheel slot is prepared in ‘ELCAM’ software to generate the computer-numerical-control (CNC) code of fir-tree-profile geometry. The experimental plan based on a trim-offset approach is executed to minimize the thermal damage and to improve the surface fatigue strength, which is most desirable for a long operating life of the jet engine. An average cutting speed of ~1.5 mm/min is observed for rough-cut and ~5 mm/min for trim-cut operation. Six categories of wires are used to manufacture the turbine wheel slots without any wire breakage and gap-short issue. The fabricated profile slots have demonstrated an average roughness (Ra) of 0.65 μm, profile accuracy within ±5 μm, minimum hardness alteration (34.87 Hv), and negligible recast layer (<5 μm) using B-150 wire and fulfilled the essential requirements of the gas turbine industries. Compared to wire-electrochemical-machining (WECM), WEDM trim-offset approach is quite advantageous and should be beneficial for the researchers working in ‘Precision machining of aerospace materials’.

本研究的目的是使用一种新颖的线电火花加工（WEDM）的微调偏移方法来精确制造涡轮机轮槽，以克服传统拉削工艺的挑战。在“ ELCAM”软件中准备了涡轮机轮槽的二维模型，以生成枞树轮廓几何形状的计算机数字控制（CNC）代码。执行基于微调偏移方法的实验计划以最小化热损伤并提高表面疲劳强度，这对于喷气发动机的长使用寿命而言是最理想的。粗切割的平均切割速度为〜1.5 mm / min，修整切割的平均切割速度为〜5 mm / min。六类金属丝用于制造涡轮机叶轮槽，而没有任何金属丝断裂和间隙短的问题。使用B-150焊丝制造的型材缝隙的平均粗糙度（Ra）为0.65μm，轮廓精度在±5μm之内，最小硬度变化（34.87 Hv），并且可忽略的重铸层（<5μm）满足了基本要求燃气轮机行业。与线电化学加工（WECM）相比，线切割（EDDM）微调偏移方法具有很大的优势，并且对从事“航空材料的精密加工”的研究人员来说应该是有益的。