Six categories of wires are used to manufacture the turbine wheel slots without any wire breakage and gap-short issue. An average cutting speed of ~1.5 mm/min is observed for rough-cut and ~5 mm/min for trim-cut operation. 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. 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 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.
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