Drilling of film cooling holes by a EDM/ECM in situ combined process using internal and side flushing of tubular electrode

Yan, Zhijie; Xu, Zhiheng; Zhu, Daiyin; Qu, Ningsong; Zhu, Yun Ming

doi:10.1007/s00170-015-7575-3

Cited by 38 publications

(11 citation statements)

References 22 publications

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“…The film cooling hole consists of a large number of small diameters [6]. Since it is difficult to implement the design of the film cooling hole in the casting method, various studies on the manufacturing method have been carried out [7,8].…”

Section: Introductionmentioning

confidence: 99%

Anisotropic Thermal Conductivity of Nickel-Based Superalloy CM247LC Fabricated via Selective Laser Melting

et al. 2021

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Efforts to enhance thermal efficiency of turbines by increasing the turbine inlet temperature have been further accelerated by the introduction of 3D printing to turbine components as complex cooling geometry can be implemented using this technique. However, as opposed to the properties of materials fabricated by conventional methods, the properties of materials manufactured by 3D printing are not isotropic. In this study, we analyzed the anisotropic thermal conductivity of nickel-based superalloy CM247LC manufactured by selective laser melting (SLM). We found that as the density decreases, so does the thermal conductivity. In addition, the anisotropy in thermal conductivity is more pronounced at lower densities. It was confirmed that the samples manufactured with low energy density have the same electron thermal conductivity with respect to the orientation, but the lattice thermal conductivity was about 16.5% higher in the in-plane direction than in the cross-plane direction. This difference in anisotropic lattice thermal conductivity is proportional to the difference in square root of elastic modulus. We found that ellipsoidal pores contributed to a direction-dependent elastic modulus, resulting in anisotropy in thermal conductivity. The results of this study should be beneficial not only for designing next-generation gas turbines, but also for any system produced by 3D printing.

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Section: Introductionmentioning

confidence: 99%

Anisotropic Thermal Conductivity of Nickel-Based Superalloy CM247LC Fabricated via Selective Laser Melting

et al. 2021

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“…Advantages of electrochemical discharge drilling were revealed by Skrabalak and Stwora [43] on the comparison study drilling hole with electrochemical, electro discharge and electrochemical discharge drilling. Zhang et al [44,45,46,47,48,49] developed new process, tube electrode high-speed electrochemical discharge drilling (TSECDD), shown in Fig 3, to machine cooling holes. Lowconductivity salt solution [44] enhanced machining surface and efficiency, increasing tube-electrode inner diameter increased MRR [45] on TSECDD.…”

Section: Ecdm Hybridsmentioning

confidence: 99%

“…Lowconductivity salt solution [44] enhanced machining surface and efficiency, increasing tube-electrode inner diameter increased MRR [45] on TSECDD. The performance of ECDD with super-high-pressure interior flushing [47] and internal and side flushing [48] were investigated with machining parameters effects. Effect of tube electrode inner diameter on ECDM of nickel-based superalloy which are widely used in aircraft engines were studied [49].…”

Section: Ecdm Hybridsmentioning

confidence: 99%

Electrochemical discharge machining: A review

Özmen¹,

Asiltürk²

2016

IJSEA

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In this study, progress and sort of electrochemical discharge machining (ECDM) that was developed to manufacture the micro features like micro grooves, micro pillar, micro holes and micro channels etc. were investigated. Many materials can be machined regardless of material conductivity, hardness and strength by ECDM using electro chemical machining (ECM) and electric discharge machining (EDM) combination. Researchers developed electrochemical discharge drilling (ECDD), turning (ECDT), grinding (ECDG), milling, dressing, trepanning, wire ECDM, die-sinking ECDM, rotary ECDM, powder mixed ECDM, magnetic field assisted ECDM, vibration assisted ECDM methods. Pyrex, glass, stainless steel, cermet, soda lime glass, quartz, silicon nitride, zirconium oxide, borosilicate glass, diamond crystals, e-glass/epoxy composite, kevlar/epoxy composite and silicon wafer were used as a work piece. Effects of machining voltage and drilling depth on mean diameter, influence of tool travel rate on groove width and depth and effects of voltage types on micro holes accuracy and machining type etc were investigated. This review is to discuss the results of studies and applicability of this methods. It sums up also with a vision for future research in electrochemical micromachining.

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“…Micro electrical discharge machining (micro-EDM) drilling is a well-established non-contact thermal process for making small holes in electrically conductive materials, such as cooling holes in turbine blades and diesel injector nozzles [1,2]. In this process, the removal of material occurs through sequences of high-frequency electrical discharges within an electrically insulated gap between two electrodes.…”

Section: Introductionmentioning

confidence: 99%

Process Fingerprint in Micro-EDM Drilling

2019

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The micro electrical discharge machining (micro-EDM) process is extensively used in aerospace, automotive, and biomedical industries for drilling small holes in difficult-to-machine materials. However, due to the complexity of the electrical discharge phenomena, optimization of the processing parameters and quality control are time-consuming operations. In order to shorten these operations, this study investigates the applicability of a process fingerprint approach in micro-EDM drilling. This approach is based on the monitoring of a few selected physical quantities, which can be controlled in-line to maximize the drilling speed and meet the manufacturing tolerance. A Design of Experiments (DoE) is used to investigate the sensitivity of four selected physical quantities to variations in the processing parameters. Pearson’s correlation is used to evaluate the correlation of these quantities to some main performance and hole quality characteristics. Based on the experimental results, the potential of the process fingerprint approach in micro-EDM drilling is discussed. The results of this research provide a foundation for future in-line process optimization and quality control techniques based on machine learning.

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Drilling of film cooling holes by a EDM/ECM in situ combined process using internal and side flushing of tubular electrode

Cited by 38 publications

References 22 publications

Anisotropic Thermal Conductivity of Nickel-Based Superalloy CM247LC Fabricated via Selective Laser Melting

Anisotropic Thermal Conductivity of Nickel-Based Superalloy CM247LC Fabricated via Selective Laser Melting

Electrochemical discharge machining: A review

Process Fingerprint in Micro-EDM Drilling

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