An electrochemical machining method for aero-engine blades based on four-directional synchronous feeding of cathode tools

Liu, Jia; Hui, Libing; Jia, Dongqian; Liu, Yan; Zhu, Di

doi:10.1016/j.cja.2022.10.003

Cited by 5 publications

(2 citation statements)

References 25 publications

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“…Electrochemical machining (ECM) is a typical non-traditional machining technology that is based on the electrochemical anodic dissolution principle to remove materials and involves electric field and flow field theories. ECM has many inherent advantages, such as independent physical properties of metal materials, no tool wear, no recasting layer or cutting force, good surface quality, and high processing efficiency [3][4][5][6][7]. After many years of development, ECM has become the mainstream manufacturing technology for complex structural components of difficult-to-process materials in aero-engines.…”

Section: Introductionmentioning

confidence: 99%

Multi-Physical Field Coupling Simulation and Experiments with Pulse Electrochemical Machining of Large Size TiAl Intermetallic Blade

Wang

Deng

et al. 2023

Metals

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Large size TiAl alloy blade is one of the important parts to reduce the weight of advanced aero-engines. However, the precision manufacturing of such blades is a challenge due to their large size, low ductility at room temperature, and high hardness of the TiAl alloy. Electrochemical machining (ECM) is a very promising method for the precision manufacturing of such blades, considering its unique advantages. In this study, a very comprehensive multi-physical field coupling simulation and pulse ECM experiments on large size TiAl alloy blades are carried out. Geometric and theoretical models involving electric fields, gas-liquid two-phase flow, heat transfer, and anodic dissolution are developed. The variation of bubble, temperature, electrolyte flow rate, and electrical conductivity at the outlet and the different areas on the blade surface with the processing time and distribution along the flow channel in the machining gap are revealed by simulation. It is found that the influence of electrolyte temperature on electrical conductivity is more dominant than that of bubble concentration. Finally, the experiments of pulse ECM on large size TiAl alloy blade are carried out, and the experimental results are analyzed in detail. The high efficiency and high surface quality of large size TiAl alloy blades are realized. The surface roughness and machining accuracy of the blade are about Ra 0.9 μm and 0.18 mm, respectively.

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Section: Introductionmentioning

confidence: 99%

Multi-Physical Field Coupling Simulation and Experiments with Pulse Electrochemical Machining of Large Size TiAl Intermetallic Blade

Wang

Deng

et al. 2023

Metals

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“…Mathematical models.-Electric field model.-During ECTr, an external voltage is loaded on the electrode, and the electric field dominates the electrochemical dissolution of the anode. The theoretical analysis of the electric field distribution in the electrolytic processing gap indicates that the electric potential distribution in the processing gap obeys the Laplace equation partition as:25…”

mentioning

confidence: 99%

Real-Time Observation of Multiphysics Coupling Fields in the Electrochemical Trepanning of Vibrating Cathodes

Wang,

Zhu,

et al. 2023

J. Electrochem. Soc.

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An electrochemical trepanning (ECTr) processing system with an observable inter-electrode gap (IEG) is designed to study the effects of vibrating cathodes on the IEG distribution. A multiphysics coupled field model for a vibrating cathode ECTr with electric, gas-liquid two-phase flow, and temperature fields is developed based on this system. The distribution laws of the current density, bubble volume fraction, and temperature in the IEG are obtained via multiphysics simulations of the coupled fields. Compared to conventional ECTr, the current density within the IEG increases, the end-gap current density percentage grows by 3%, and the electrolyte renewal within the IEG is promoted. An experimental study of a vibrating cathode ECTr verifies the validity of the simulations. A distinct white bubble layer appeared at the transition corner of the end gap near the cathode side. The bubbles were gradually increasing as the cathode was fed to the workpiece during a cycle. No obvious white bubble layer is seen at the side gap. The observations verify the multiphysics field simulations to study the gas volume fraction distribution law. The experimental results show that the vibrating cathode improves the integrity of the blade profile and surface quality.

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Electrochemical machining of complex structures on thin-walled plates using pure rolling cathode tool

Zhu,

Wang,

Zhu

2024

Int J Adv Manuf Technol

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An electrochemical machining method for aero-engine blades based on four-directional synchronous feeding of cathode tools

Cited by 5 publications

References 25 publications

Multi-Physical Field Coupling Simulation and Experiments with Pulse Electrochemical Machining of Large Size TiAl Intermetallic Blade

Multi-Physical Field Coupling Simulation and Experiments with Pulse Electrochemical Machining of Large Size TiAl Intermetallic Blade

Real-Time Observation of Multiphysics Coupling Fields in the Electrochemical Trepanning of Vibrating Cathodes

Electrochemical machining of complex structures on thin-walled plates using pure rolling cathode tool

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