Research on the characteristics of multiphysics coupling fields in the electrochemical trepanning of an inward facing blisk

Jiao, erhao; Zhu, Daiyin; Zhang, Chao; Wang, Peng-Hui; Zuo, Hang

doi:10.1016/j.jmapro.2023.03.009

Cited by 3 publications

(4 citation statements)

References 34 publications

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“…Although the machining distance varies according to the machining parameters, it ranges between 0.2 and 2 mm for such assemblies (Guo et al ., 2023; Wang et al ., 2021a, b; Zhu et al ., 2013). The electrolyte type NaNO3 or NaCl is preferred and its conductivity usually ranges between 70 and 150 mS.cm- 1 (Jiao et al ., 2023; Wang et al ., 2023; Zhang et al ., 2022). During electrolyte transfer, pumps that can provide high pressure with high flow rate are used to improve the surface quality.…”

Section: Finite Element Analysis Of Blisk Bladesmentioning

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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Section: Finite Element Analysis Of Blisk Bladesmentioning

confidence: 99%

Investigation of electrolyte pressure effect on blisk blades during electrochemical machining

Aslan,

Kanber,

Demirtas

et al. 2024

MMMS

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“…(1) Oxygen generated on the workpiece is neglected; (2) boundary is set to no sliding; (3) generated Joule heat does not escape. 22 In the electric field model, the boundary satisfies:…”

Section: Multiphysics Coupling Simulationsmentioning

confidence: 99%

“…21 Jiao et al proposed a cambered cathode structure that improved the flow field uniformity and enhanced the blade forming accuracy and surface quality. 22 Wang et al proposed a machining process with a small fluctuating IEG to improve the machining accuracy and surface quality. 23 There are few studies on multiphysics field simulations of ECTr using vibrating cathodes, and physical field observations in the IEG have not been studied.…”

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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“…Their theoretical models will be analyzed in detail. The simulation is carried out by the commercial simulation software COMSOL [25][26][27].…”

Section: Model Of Multi-physical Field Coupling Simulationmentioning

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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Research on the characteristics of multiphysics coupling fields in the electrochemical trepanning of an inward facing blisk

Cited by 3 publications

References 34 publications

Investigation of electrolyte pressure effect on blisk blades during electrochemical machining

Investigation of electrolyte pressure effect on blisk blades during electrochemical machining

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

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

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