Numerical control electrical discharge machining(NC EDM) is one of the most widely used machining technologies for manufacturing a closed blisk flow path, particularly for three-dimensional(3D) curved and twisted flow channels. In this process, tool electrode design and machining trajectory planning are the key factors affecting machining accessibility and efficiency. Herein, to reduce the difficulty in designing the electrode and its motion path in the closed curved and twisted channels, a heuristic search hybrid optimisation strategy based on channel grids is adopted to realise the initial electrode trajectory design search and optimised size reduction. By transferring the trajectory optimisation constraints from the complex free-form surface to numbered grids, the search is found to be more orderly and accurate. The two trajectory indicators, namely argument angle and minimum distance, are analysed separately for the optimised results of the adaptive learning particle swarm optimisation algorithm, demonstrating that they can meet the actual processing requirements.Experimental results of NC EDM indicate that the motion path generated by this design method can meet the machining requirements of 3D curved and twisted flow channels.
