###### Abstract  
Electrochemical machining (ECM) is one of the main methods for manufacturing gamma-titanium aluminum (\(\gamma\)-TiAl) alloy blades of new-type aero-engines. Tool-vibration-assisted pulsed electrochemical machining (VPECM) is an important method to improve the manufacturing accuracy. In order to determine the influence of processing parameters on the VPECM quality of \(\gamma\)-TiAl TNM alloys, multi-field simulations with different parameter combinations of peak voltage, feed rate, duty cycle, and tool vibration frequency were carried out. The influence of bubble rate and temperature increase on the conductivity distribution in the machining gap under different parameter combinations was analyzed. Then, orthogonal experiments with the above four processing parameters were carried out. The experimental results of surface roughness, replication accuracy, and average current density in the pulse width were interpreted by a grey relational analysis, and the best parameter combination was determined. Finally, four blade-shaped \(\gamma\)-TiAl TNM alloy specimens were processed by using the optimized parameter combination, which had good replication accuracy and surface quality. electrochemical machining (ECM); parameter optimization; multi-field simulations; \(\gamma\)-TiAl TNM blades 2022202202202202202022022020202202022020220202202022020220220202202022022022020  
they found that it was easier to obtain a better-quality machined surface in the sodium chloride solution, and the surface of \(\gamma\)-TiAl alloys processed by ECM had no obvious defects compared with the cutting process [12]. [PERSON] et al. analyzed the electrochemical dissolution characteristics of \(\gamma\)-TiAl with different compositions and found that, compared with traditional titanium alloys, \(\gamma\)-TiAl alloys have higher processing efficiency due to their increased aluminum content [13]. British company Rolls Royce processed a \(\gamma\)-TiAl 45 XD casting blank by ECM, and, after processing the airfoil profile, the edge plate was prepared by machining, and the \(\gamma\)-TiAl 45 XD blade was successfully obtained [4]. [PERSON] et al. analyzed the anodic dissolution characteristics of two new light alloy materials (\(\gamma\)-TiAl 4822 and 45 XD) in ECM experiments, and the microstructure and surface morphologies of the workpieces were examined [14]. [PERSON] et al. investigated the electrochemical dissolution behavior of \(\gamma\)-TiAl 4822 to improve the machining efficiency and surface quality obtained by ECM, and the results showed that \(\gamma\)-TiAl 4822 had a higher material removal rate in NaCl and higher surface quality in NaNO\({}_{3}\)[15]. [PERSON] et al. presented a generic ECM anti-copy method with machining gap control to process \(\gamma\)-TiAl blades, and the test specimens showed good quality and high accuracy [16]. The processing mode of the above research mainly adopted direct-current (DC) and pulsed ECM processing. Tool-vibration-assisted pulsed ECM (VPECM) is a type of precision electrolytic processing method that creates the pulse width in small machining gaps and pulse interval in large machining gaps [17; 18]. The vibration of the tools will enhance the ability of the electrolyte to discharge electrolytic products. Compared with the DC and pulsed ECM methods, VPECM can achieve a smaller machining gap and higher machining accuracy [19; 20]. Therefore, VPECM is expected to improve the ECM precision of \(\gamma\)-TiAl alloys. In this paper, an experimental study on parameter optimization was carried out for the VPECM of \(\gamma\)-TiAl TNM alloy. Through a multi-field simulation analysis of different parameter combinations in VPECM, such as peak voltage, feed rate, duty cycle, and tool vibration frequency, the influence of the bubble rate and temperature rise on the conductivity distribution in the machining gap with different parameter combinations was revealed. Then, orthogonal experiments with the above four processing parameters were carried out.