With the rapid development of aerospace industry in recent years, the use of aero-rotor engine blades with new special alloy materials and high distortion and thin-walled structure has been paid more and more attention. Aiming at the problems of poor tool accessibility, serious tool loss and easy deformation of blade profile in NC milling technology, electrochemical machining can realize the processing of complex special structure products with advanced materials by means of non-contact electrochemical etching process. However, in the process of electrochemical etching, the flow channel structure of electrochemical machining affects the stability of the distribution of electrochemical etching characteristics in various parts of the machining surface and ultimately acts on the forming quality by controlling the liquid phase mass transfer process in the machining gap. Therefore, reasonable design and optimization of the flow channel is of great significance in the process of electrochemical machining. In this paper, based on the existing traditional vertical single-axis feed machining mode and combined with the traditional side flow processing blade flow characteristics, innovatively proposed two kinds of electrolyte flow schemes under the vertical machining mode; Then, based on the above two flow channel structures and the energy loss characteristics of viscous fluid during liquid phase mass transfer, a mathematical model of liquid phase mass transfer flow field is established, which combines the viscosity loss characteristics of electrolyte, and by introducing a optimized flow channel structure that combined with the characteristics of positive flow and side flow and adjusting the parameters of electrolyte inlet / outlet, the optimal design channel structure and uniform flow field of aero-rotor blades are realized. Finally, the accuracy and rationality of the proposed scheme are verified by electrochemical machining verification test, which lays a research foundation and guarantee for the feasibility and accuracy of vertical electrochemical machining machine tool in aero-rotor blades.
To address the problems of serious tool loss and the easy deformation of aero-rotor blade profiles in NC milling technology, electrochemical machining can realize the processing of complex, specially structured products with advanced materials such as nickel alloy Inconel®718 by means of a non-contact electrochemical etching process. In this paper, by analysing the electrochemical reaction state of Inconel®718 alloy in vertical electrolytic processing, the electrolyte side flow of aero-blade electrochemical machining technology is innovatively transplanted to the traditional vertical single-axis feed machining tool, and the corresponding optimized flow channel structure that combines the characteristics of positive flow mode and side flow mode are proposed. Then, the verification test shows that the vertical machining of aero-blade with the characteristics of positive flow and side flow of electrolyte has high machining quality, and its surface error is in the range of 0.02-0.12 mm (the average surface error can reach 0.07 mm), the corresponding surface roughness is 1.16 µm. Therefore, the research foundation and technical potential are laid for the vertical electrochemical machining of the aero-rotor blades.
A landing gear is the main large bearing structural part of an aircraft. The change of material and structure makes the processing of the aircraft landing gear more difficult. Aiming at the structural characteristics of the aircraft landing gear deep cavity, the deep hole processing technique of a 300M steel workpiece was studied. A separated NC deep hole drilling and boring machine was adopted to process the workpiece. Cavity hole special cutting tools were introduced. Fixture and sealing mode were improved. NC programs were optimized. Thus, the processing problems of deflection, vibration, chip breaking and chip removal were solved. The workpiece with width to diameter ratio greater than 10 and surface roughness of hole is 3.2 μm was successfully machined by machining experiment, and the high efficiency machining of deep hole of ultra-high strength steel was realized. Thus the theoretical foundation is laid for the machining of complex cavity deep holes for cutting high-strength alloy materials.
In the oil exploration work, the hammer rod as the main component, due to the insufficient strength of the hammer rod, the hammer head falling off, the hammer body bending deformation and copper layer falling off and other problems often occur in the work, which not only affects the exploration progress but also causes huge economic losses. Aiming at the problem of insufficient strength of the hammer rod, through the analysis of the processing technology of the hammer rod and the working environment of the hammer rod, it is concluded that there are problems in the design of the hammer head, the material selection of the hammer body, and the processing technology of the copper layer. In this regard, the design of the hammer head is optimized, the depth of the inner hole of the hammer head is deepened, and the inner hole of the hammer head is changed to a taper hole; replace the 2CrMo alloy steel with higher strength as the main material of the hammer body, and add a heat treatment process after the rough turning to release the residual stress inside the hammer body; the processing process scheme for replacing the copper layer is attached to the surface of the hammer body by means of a hot-mounted copper sleeve. The improved hammer rod strength fully meets the needs of high-intensity impact work, shortens the exploration time, saves exploration costs, and makes great contributions to the exploration work.
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