Simulation and Experimental Study on Slow Wire Electrical Discharge Machining of GH4169

To investigate the influence of slow wire electrical discharge machining process parameters on machining quality and accuracy, this study employed COMSOL software combined with the finite element method to perform transient thermal simulations of single-pulse discharge during the wire cutting process. The formation process of discharge craters was simulated, and the formation mechanism of the machined surface micro-morphology was analyzed. Meanwhile, single-factor machining experiments were conducted to verify the accuracy of the simulation results.The results showed that both the radius and depth of the discharge craters increased with increasing pulse width and peak current, which led to higher surface roughness and deterioration of surface quality. The experimental results confirmed the interaction relationship between the surface morphology produced by wire electrical discharge machining and the discharge parameters, providing valuable guidance for practical machining processes.