发动机叶片电解加工阴极设计的基础研究

结合某型发动机的叶片进行几何造型,建立电解加工间隙的成形规律关系式,分析叶片空间法线与进给方向夹角的分布情况并确定阴极进给方向,进行阴极型面设计。     

扩压器扭曲型面电解加工阴极进给方向优化及试验

电解加工(ECM)是一种非接触式加工工艺,阴极进给方向对最终的加工精度有重要影响。斜向叶片式扩压器轮毂面较为扭曲,针对其叶片型面电解加工,提出了一种基于遗传算法的阴极进给方向综合优化方法。该方法将夹角的最大值和阴极侧面与轮毂面之间的间隙方差同时作为遗传算法的评价指标,在保证夹角最大值相对较小的情况下,使得阴极侧面与轮毂面之间的间隙分布更加均匀,从而避免轮毂面发生余量不均或过切现象。为了验证该优化方法的有效性,基于优化结果进行了夹具设计并开展扩压器电解加工试验,结果表明,叶片型面加工误差小于0.12 mm,轮毂无过切现象,实现了该扩压器的电解精加工。     

超薄扭曲叶片精密电解加工

介绍了由方料经单面电解加工超薄扭曲叶片叶身型面的方法．以及其零件加工难点、夹具和阴极结构及非加工面的保护．用该方法批生产叶片、叶身型面重复制造精度稳定，型面轮廓精度基本满足了无余量修抛要求．     

大扭曲叶片整体涡轮电解加工工艺研究

研究用展成电解工艺进行大扭曲度整体涡轮叶片的机械加工，对涡轮叶片型面进行数据处理，用软件方式实现电解加工的多轴联动进给；分析叶片电解过程成形规律，合理设计阴极、流场，解决大扭曲叶片加工的叶背二次腐蚀、出口短路等关键工艺问题，试验可稳定达到工序精度要求，并可批量生产。     

叶片型面精密振动电解加工工艺研究

采用电解加工工艺对叶片型面进行加工,可以有效提高发动机叶片加工效率,降低生产成本。针对GH4169G合金叶片型面,开展了精密振动电解加工试验研究。结果表明:高频脉冲电流和阴极机械振动具有改善极间流场特性、降低阳极钝化和阴极的产物吸附的作用,可以大幅改善加工效果;采用参数组加工电压15V、阴极振动频率25Hz、开通角度Ra 150°~195°、脉冲频率3000Hz时,获得最优的型面加工质量,型面轮廓度为-0.012~+0.013mm,表面粗糙度值为0.51μm,证明精密振动电解加工工艺满足叶片型面的加工要求。     

方坯叶片电解成形规律的探讨

从电解加工过渡过程公式出发，分析了方料毛坯叶片型面直接电解成形的特殊规律，讨论了方坯阴极反拷法的制造过程，提出了基干提高方坯叶片电解成形精度的措施。     

振动进给脉冲电流电解加工

电解加工是50年代后期出现的一种新工艺,加工时(见图1)工具电极(阴极)与直流电源负极相连,零件(阳极)与直流电源正极相连,两极间通以高速流动的电解液。此外,电极还向零件匀速进给。结果电极的形状就相应地复制在零件上。由于这种加工方法最适宜难加工材料和复杂型面的加工,例如叶片型面、异形孔槽和锻模型腔等的加工,因而在航空发动机厂获得了普遍应用。但是为了继续扩大应     

异形曲面电解加工进给运动分析与设计

介绍了整体构件异形曲面的特点、应用及加工现状,分析了异形曲面电解加工的展成运动方式,讨论了直纹面整体构件叶片间通道电解加工及异形曲面电解光整加工的进给运动参数设计方法。     

内喷式阴极电解加工整体叶轮叶间通道的间隙特性

本文介绍了在内喷式阴极展成电解加工整体叶轮叶间通道时，加工电压、阴极进给速度、电解液压力和温度对加工间隙的影响，经过对其试验数据所作分析，得出了一些有益的结论，为展成电解加工整体叶轮提供了试验与理论依据。     

整体构件异形曲面电解加工运动分析与设计

为了解决整体构件异形曲面的加工难题，提出了展成电解加工及电解光整加工的方法，分析展成运动方式，讨论确定机床进给运动方案，重点探讨直纹面整体构件叶片间通道电解加工及异形曲面电解光整加工的进给运动参数设计方法，分析并给出合理的流场设计方案。通过优化异形曲面电解加工的数控编程、完善工艺设计与试验，最终加工出了合格件。     

Trajectory control strategy of cathodes in blisk electrochemical machining

A turbine blisk, which combines blades and a disk together, is one of the most important components of an aero engine. In the process of blisk electrochemical machining (ECM), the sheet cathode, which is usually used as a tool electrode, has a complicated structure. In addition to that, the channel between the adjacent blades is narrow and twisted, so interference is apt to happen when the sheet cathode feeds into the channel. Therefore, it is important to choose suitable trajectory control strategy. In this paper, a new trajectory control strategy of the sheet cathode is presented and corresponding simulation analysis is conducted on the basis of an actual blisk model. The simulation results demonstrate that the sheet cathode can feed into the channel by a spatial line trajectory without interference. Moreover, the verification experiments are carried out according to the simulation. The experimental results show that the cathode can move into the channel without interference. It is verified that the new trajectory control strategy is correct and can be used in the blisk ECM process successfully.     

Cathode design investigation based on iterative correction of predicted profile errors in electrochemical machining of compressor blades

Electrochemical machining (ECM) is an effective and economical manufacturing method for machining hard-to-cut metal materials that are often used in the aerospace field. Cathode design is very complicated in ECM and is a core problem influencing machining accuracy, especially for complex profiles such as compressor blades in aero engines. A new cathode design method based on iterative correction of predicted profile errors in blade ECM is proposed in this paper. A math-ematical model is first built according to the ECM shaping law, and a simulation is then carried out using ANSYS software. A dynamic forming process is obtained and machining gap distributions at different stages are analyzed. Additionally, the simulation deviation between the prediction profile and model is improved by the new method through correcting the initial cathode profile. Further-more, validation experiments are conducted using cathodes designed before and after the simulation correction. Machining accuracy for the optimal cathode is improved markedly compared with that for the initial cathode. The experimental results illustrate the suitability of the new method and that it can also be applied to other complex engine components such as diffusers.     

基于电解扫掠成形原理的整体叶盘叶根加工方法

采用片状或管状阴极电解加工(ECM)后的整体叶盘由于加工运动、阴极形状等原因在叶根处会形成一定的加工残留,影响整体叶盘的加工精度。针对叶片电解加工后形成的叶根残留,开展去除叶根残留电解加工方法的研究,解决叶根电解加工的阴极结构、加工路径设计等难题。首先,分析了叶根的残留分布情况以及叶间通道的结构,采用了电解扫掠成形加工方案。其次,设计了阴极结构与加工路径,在阴极结构上采用了扇形流道并分析了电解液流速分布,通过增加引流槽、改变倾角等措施改善了流场;对阴极的运动路径进行了规划,利用专用仿真软件对阴极运动干涉与加工程序进行了检验;通过附加叶盘转动补偿了由于不同截面内叶间通道宽度与阴极刃口尺寸不一致给加工带来的不足。最后,制作了电解加工装置并通过试验对叶根电解加工方法进行了验证。试验结果表明,该加工方法有效去除了叶根残留,加工表面质量好,加工精度达到了要求。     

Electrochemical trepanning with uniform electrolyte flow around the entire blade profile

In the traditional machining process for diffusers, blades are easily deformed, and methods suffer from high tool wear and low efficiency. Electrochemical machining(ECM) possesses unique advantages when applied to these difficult-to-machine materials. In the ECM process, theflow field plays a crucial role. Here, an electrolyte flow mode that supplies uniform flow around the entire blade profile was adopted for electrochemical trepanning of diffusers. Various flow rates were employed to obtain the optimal flow field. Simulations were conducted using ANSYS software, and results indicated that increasing the flow rate substantially afforded a more uniform flowfield. A series of experiments was then performed, and results revealed that increasing the flow rate greatly improved both the machining efficiency and the surface quality of the diffusers. The maximum feeding rate of the cathode reached 4 mm/min, the blade taper of the concave part decreased to 0.02, and the blade roughness was reduced to 1.216 lm. The results of this study demonstrated the high feasibility of this method and its potential for machining other complex components for engineering applications.     

Simulation and experimental investigation of inner-jet electrochemical grinding of GH4169 alloy

GH4169 alloy is one of the most commonly used materials in aero engine turbine blades, but its machinability is poor because of its excellent strength at high temperatures. Electrochemical machining (ECM) has become a common method for machining this alloy and other difficult-to-machine materials. Electrochemical grinding (ECG) is a hybrid process combining ECM and conventional grinding. In this paper, investigations conducted on inner-jet ECG of GH4169 alloy are described. Two types of inner-jet ECG grinding wheels were used to machine a flat bottom surface. The machining process was simulated using COMSOL software, and machining gaps under different machining parameters were obtained. In addition, maximum feed rates and maximum material removal rates under different machining parameters were studied experimentally. The maximum sizes and the uniformity of the distributions of the gaps machined by the two grinding wheels were compared. The effects of different applied voltages on the machining results were also investigated.     

整体叶盘叶型电解加工流场设计及实验简

 电解加工（ECM）是航空发动机整体叶盘制造的主要技术之一,其电解液流场稳定性是影响电解加工精度和表面质量的核心因素。本文在分析原有的二维流场基础上,针对流体在不同流道截面下的流场状态,提出了一种三维复合电解液流场模式,即三股电解液分别从毛坯进气边、叶盆叶根、叶背叶根流入,由排气边交汇流出。采用有限元法对三维复合流场及两类二维流场开展仿真分析,分析结果表明三维复合流场改善了流道突变区域流场状态,有效抑制了二维流场的流场缺陷,有助于提高流场稳定性。对加工区液体流态进行了判断,其结果显示三维复合流场可以满足电解加工要求。开展了3种流场模式的加工速度比较实验,三维复合流场达到的进给速度最高,较二维流场可显著提升加工效率。采用三维复合流场开展了多叶片扇段加工,获得了较好的重复精度与表面质量。     

整体叶盘叶型电解加工流场设计及实验

电解加工（ECM）是航空发动机整体叶盘制造的主要技术之一,其电解液流场稳定性是影响电解加工精度和表面质量的核心因素。本文在分析原有的二维流场基础上,针对流体在不同流道截面下的流场状态,提出了一种三维复合电解液流场模式,即三股电解液分别从毛坯进气边、叶盆叶根、叶背叶根流入,由排气边交汇流出。采用有限元法对三维复合流场及两类二维流场开展仿真分析,分析结果表明三维复合流场改善了流道突变区域流场状态,有效抑制了二维流场的流场缺陷,有助于提高流场稳定性。对加工区液体流态进行了判断,其结果显示三维复合流场可以满足电解加工要求。开展了3种流场模式的加工速度比较实验,三维复合流场达到的进给速度最高,较二维流场可显著提升加工效率。采用三维复合流场开展了多叶片扇段加工,获得了较好的重复精度与表面质量。     

阴极调速法测定电解加工ηω-i曲线特性的试验研究及其应用

镍基高温合金GH4169是航空发动机叶片的常用材料。为了精确获取GH4169的ηω-i曲线特性,采用调节阴极进给速度的新方法,实时控制加工间隙,使加工过程迅速过渡到平衡状态。利用阴极调速法开展了电解加工试验,经过计算得出ηω-i曲线。结果表明:当电流密度i小于6A/cm2时,ηω值趋向于0;当i大于50A/cm2时,ηω保持在1.28mm3/(A.min)不变。针对某航空发动机叶片,基于阴极调速法和恒速法测定的ηω-i曲线特性,分别设计了工具阴极,并开展了对比工艺试验研究。研究表明:根据阴极调速法测得ηω-i曲线特性设计的阴极,加工出叶片的复制精度明显提高,叶片精度整体提高0.03mm,证明该方法测定ηω-i曲线特性更加准确。