Regulation Mechanism of Multi-Hole Flushing and Modular Bundle Electrode Dynamic Flow Field Coupling on EDM Performance of Titanium Alloys

This study presents an innovative approach to enhance electrical discharge machining (EDM) of titanium alloys through synergistic integration of modular bundled electrodes and multi-hole dielectric flushing. Addressing challenges posed by titanium alloys' low thermal conductivity—including inefficient material removal and severe electrode wear—we develop a dynamic flow field regulation system combining geometric optimization of electrode arrays with computational fluid dynamics (CFD) modeling. ANSYS Fluent simulations reveal that multi-channel flushing achieves a radial velocity gradient from 2.35×10<sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">⁻3</sup> m/s to 0.92 m/s, enhancing debris evacuation efficiency by 2.1× compared to single-channel systems. Experimental validation demonstrates a material removal rate of 77.9 mm<sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sup>/min using bundled electrodes, representing a 2.78× improvement over conventional solid electrodes, while maintaining interfacial stress uniformity below 1.9×10<sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">⁵</sup> N/m<sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sup>. The modular architecture ensures mechanical stability under operational loads through finite element analysis-optimized clamping forces, effectively mitigating electrode deformation risks. Flow field characterization confirms 60% improvement in inter-electrode velocity uniformity, critical for suppressing secondary discharges and thermal accumulation. This work establishes a transformative framework for high-precision machining of aerospace-grade titanium alloys, bridging critical gaps between flow field dynamics, electrode design, and process stability in industrial EDM applications.