Electrochemical machining on blisk cascade passage with dynamic additional electrolyte flow

Zhu, Daiyin; Zhang, Juchen; Zhang, Kuanglei; Liu, Jia; Zhu, Chen; Qu, Ningsong

doi:10.1007/s00170-015-7043-0

Cited by 34 publications

(7 citation statements)

References 20 publications

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“…To ensure the electrolyte in a turbulent state, the Reynolds number should be greater than 2300. So, the electrolyte flow velocity satisfies the formula as follows [15]:…”

Section: Finite Element Equations Of Electrolyte Flowmentioning

confidence: 99%

Electrochemical Machining Multiple Slots of Bipolar Plates with Tool Vibration

Jiang¹,

Astronautics²

2018

International Journal of Electrochemical Science

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A bipolar plate is an important component of proton exchange membrane fuel cells (PEMFC). The fabrication of multiple slots is a key part in preparation of metallic bipolar plates. They can be produced by electrochemical machining (ECM). During the ECM process, high flow resistance occurs with the increase of slots length and depth, which will make metal hydroxide and other by-products accumulate in the outlet of electrolyte and limit the maximum feed rate of cathode. Therefore, a flow channels contraction cathode structure with variable cross-section has been proposed. It can make the flow velocity of electrolyte increase gradually in the inter-electrode gap and take away electrolysis products better. In order to remove electrolysis products further, tool vibration is applied. The flow channels contraction cathode has been determined with numerical simulations, and the comparison experimental results show that the way is effective in improving the feed rate and ensuring the uniformity of slots depth.

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“…To ensure the electrolyte in a turbulent state, the Reynolds number should be greater than 2300. So, the electrolyte flow velocity satisfies the formula as follows [15]:…”

Section: Finite Element Equations Of Electrolyte Flowmentioning

confidence: 99%

Electrochemical Machining Multiple Slots of Bipolar Plates with Tool Vibration

Jiang¹,

Astronautics²

2018

International Journal of Electrochemical Science

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“…Material of the structure is HT250, the density i s ρ = 7 . 0 × 1 0 3 k g / m 3 Low-order natural frequency has greater influence on structural stiffness; therefore, when doing modal analysis, only the first five natural frequencies need to be considered. Use the Block Lanczos method to analyze and ANSYS to solve, calculation results are shown in Table 1 and vibration modes are shown in Fig.…”

Section: Static and Dynamic Analysesmentioning

confidence: 99%

“…Recently, there emerging many novel methods for blisk manufacturing. An efficient electrochemical machining method for blisk channels is proposed in [3,4], which can process multi channels at the same time. Electrical discharge machining (EDM) is used in blisks machining and the tool electrode is shaped and reduced based on the profile of the flow channels [5].…”

Section: Introductionmentioning

confidence: 99%

Structure design and rotation control of the disc milling head in blisk manufacturing

Zhao

Huang

Shi

2016

Int J Adv Manuf Technol

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Blisks are the most important and critical components in the gas turbine engines, which could reduce the weight obviously and improve the efficiency significantly. To achieve high efficient machining of the titanium-based blisk, a powerful and composite processing method is proposed and structure of disc milling head with high stiffness and high precision is designed, including mechanical transmission, electrical system, rotating control, locking device, and tool changer. Then, static and dynamic analyses are carried out for the disc milling head, and calculation results show that the static and dynamic performances are perfect, which satisfy the processing requirements. Considering friction and backlash in the worm gear transmission, parameters perturbation in the electrical control system, and process noise and measurement noise in the system have serious impact on the positioning precision of disc milling rotation system, a robust sliding mode control (SMC) algorithm based on linear quadratic optimal control (LQC) is proposed. Based on the traditional LQC, introduce the state estimation based on Kalman filter and control input, improve the system state space model, and define a new sliding surface equation, then, a robust SMC based on LQC is finished. Simulation and experiment results show that the designed controller is robust to the nonlinearities and uncertainties in the rotation control system of disc milling head and can achieve high positioning precision.

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“…Using 0.4 MPa and 0.8 MPa electrolyte pressure, the flow field of the electrolyte was studied in the simulation environment. In the experimental study by Zhu et al ., (2015a, b), different electrolyte pressures between 0.4 and 1 MPa were used. During machining, the regions where the electrolyte flow is insufficient on the blade surface depending on the pressure values were examined.…”

Section: Introductionmentioning

confidence: 99%

Investigation of electrolyte pressure effect on blisk blades during electrochemical machining

Aslan,

Kanber,

Demirtas

et al. 2024

MMMS

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PurposeThe purpose of this study is analysis of deformation and vibrations of turbine blades produced by high electrolyte pressure during electrochemical machining.Design/methodology/approachAn experimental setup was designed, experiments were conducted and the obtained results were compared with the finite element results. The deformations were measured according to various flow rates of electrolyte. In finite element calculations, the pressure distribution created by the electrolyte on the blade surface was obtained in the ANSYS® (A finite element analysis software) Fluent software and transferred to the static structural where the deformation analysis was carried out. Three different parameters were examined, namely blade thickness, blade material and electrolyte pressure on blade disk caused by mass flow rate. The deformation results were compared with the gap distances between cathode and anode.FindingsLarge deformations were obtained at the free end of the blade and the most curved part of it. The appropriate pressure values for the electrolyte to be used in the production of blisk blades were proposed numerically. It has been determined that high pressure applications are not suitable for gap distance lower than 0.5 mm.Originality/valueWhen the literature is examined, it is required that the high speed flow of the electrolyte is desired in order to remove the parts that are separated from the anode from the machining area during electrochemical machining. However, the electrolyte flowing at high speeds causes high pressure in the blisk blades, excessive deformation and vibration of the machined part, and as a result, contact of the anode with the cathode. This study provides important findings for smooth electro chemical machining at high electrolyte flows.

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Electrochemical machining on blisk cascade passage with dynamic additional electrolyte flow

Cited by 34 publications

References 20 publications

Electrochemical Machining Multiple Slots of Bipolar Plates with Tool Vibration

Electrochemical Machining Multiple Slots of Bipolar Plates with Tool Vibration

Structure design and rotation control of the disc milling head in blisk manufacturing

Investigation of electrolyte pressure effect on blisk blades during electrochemical machining

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