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。     

Flow field design and process stability in electrochemical machining of diamond holes

The metal grille, commonly composed of an amount of diamond holes, has been grow-ingly used as a key structure on stealth aircraft. Electrochemical machining (ECM) promises to be increasingly applied in aircraft manufacturing on the condition that process stability is guaranteed. In this work, a flow field model was designed to improve the process stability. This model is endowed with a variety of flow channel features, together with vibrating feeding modes. The flow field distribution on the bottom surface of the diamond hole was discussed and evaluated as well. The numerical results show that a short arc flow channel could significantly enhance the uniformity of electrolyte velocity distribution and a vibrating feeding of the cathode enables to reduce both fluctuations of the electrolyte velocity and pressure on the bottom surface of the diamond hole. Consequently, the flow field mutations were eliminated. It is verified from the experimental results that a short arc flow channel, when combined with vibrating feeding, is capable of improving machining localization and process stability markedly. What is more, the side gap on the bottom surface of the diamond hole could also be reduced by the abovementioned approach.     

Flow field design and experimental investigation of electrochemical machining on blisk

Flow field is a crucial factor to influence the stability and surface quality in the electrochemical machining (ECM) of blisks. A four-way flow mode was proposed to eliminate mixing regions of electrolyte at the leading and tailing edges. Two flow field models were described separately in this report: a W-shaped flow mode and a four-way flow mode. The flow field was analyzed through a finite element method. The results showed that, in comparison with the W-shaped flow mode, the distribution of electrolyte flow was more uniformed and the mixed region in the flow channel was improved. The pressure of the leading and tailing edges inlets was optimized, and optimal pressure of 0.6 MPa was determined. In addition, verification experiments were performed, and the results showed that the stability, efficiency, and quality of the profiles of the blisk blade manufactured by ECM were enhanced in the new flow mode.     

Simulation and experimental investigation on a dynamic lateral flow mode in trepanning electrochemical machining

An appropriate flow mode of electrolyte has a positive effect on process efficiency, surface roughness, and machining accuracy in the electrochemical machining(ECM) process. In this study, a new dynamic lateral flow mode, in which the electrolyte flows from the leading edge to the trailing edge, was proposed in trepanning ECM of a diffuser. Then a numerical model of the channel was set up and simulated by using computational fluid dynamics software. The result showed that the distribution of the flow field was comparatively uniform in the inter-electrode gap. Furthermore, a fixture was designed to realize this new flow mode and then corresponding experiments were carried out. The experimental results illustrated that the feeding rate of the cathode reached 2 mm/min, the best taper angle was about 0.4°, and the best surface roughness was up to Ra= 0.115 lm. It reflects that this flow mode is suitable and effective, and can also be applied to machining other complex structures in trepanning ECM.     

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.     

合成射流对圆柱绕流流固耦合特性影响分析

利用合成射流对钝体绕流流动特性及流致振动进行了主动控制数值研究。结果表明:随着合成射流动量系数的增加,对圆柱涡激振动的抑制效果越好。随着射流位置从后驻点移向前驻点,圆柱尾流涡脱模态呈现出柱体背流面附着对称涡的定常状态-过渡状态-反对称2S涡脱落模式的演变过程。圆柱双自由度振动轨迹为“8”字形,完全受到抑制时轨迹为“一”字型,部分抑制时其轨迹为“月牙形”,合成射流的引入可有效降低圆柱所受升力,能有效的抑制圆柱横向和流向振动,当合成射流对位于圆柱背风侧的1/4弧边缘时,圆柱的流向振荡和横流振荡均可被抑制,其抑制效果最好。      

Optimization of flow field in electrochemical trepanning of integral cascades (Ti6Al4V)

Ti6Al4V is widely applied in the integral cascades of aero engines. As an effective machining method, electrochemical trepanning (ECTr) has unique advantages in processing surface parts made of hard-to-cut materials. In ECTr, the state of the flow field has a significant effect on processing stability and machining quality. To improve the uniformity of the flow field when ECTr is applied to Ti6Al4V, two different flow modes are designed, namely full-profile electrolyte supply (FPES) and edges electrolyte supply (EES). Different from the traditional forward flow mode, the flow directions of the electrolyte in the proposed modes are controlled by inlet channels. Simulations show that the flow field under EES is more uniform than that under FPES. To further enhance the uniformity of the flow field, the structure of EES is optimized by modifying the insulating sleeve. In the optimized configuration, the longitudinal distance between the center of the inlet hole and the center of the blade is 6.0 mm, the lateral distance between the centers of the inlet holes on both sides is 16.5 mm, the length to which the electrolyte enters the machining area is 1.5 mm, and the height of the insulating sleeve is 13.5 mm. A series of ECTr experiments are performed under the two flow modes. Compared with EES, the blade machined by FPES is less accurate and has poorer surface quality, with a surface roughness (R_a) of 3.346 μm. Under the optimized EES, the machining quality is effectively enhanced, with the surface quality improved from R_a = 2.621 μm to R_a = 1.815 μm, thus confirming the efficacy of the proposed methods.     

不同压比状态下超声速射流冲击斜板的声场/流场特性

为研究超声速射流冲击斜板的噪声特性及声源特性,针对不同压比下,超声速射流流场及声场分别进行了高频PIV（particle image velocimetry)测量与远场噪声测量。PIV测量结果可观测到激波格栅形成过程以及冲击斜板对它的影响。声场测量结果可捕捉到自由射流与冲击射流中不同的纯音频率随压比增加的转变过程。通过一一对比各纯音模态与流场模态,可区分各纯音模态的声源特性。结果表明:当压比在2.0~3.2之间时,共出现五种纯音模态:A模态纯音频率为剪切层大尺度涡脱落频率,此时流场呈现同轴模态;d模态和e模态中纯音频率主要为冲击纯音频率,且e模态出现时流场转化为螺旋模态,这是一种不稳定模态;当压比大于等于2.53时,纯音模态稳定成单一模态B,B模态纯音频率为啸叫频率,其流场结构转化回同轴模态,啸叫频率对斜板的存在与否不敏感;啸叫频率随着压比的增加逐渐减小,其二次谐频在基频幅值较小的方向上会出现一个强声波辐射。      

低负荷和高负荷压气机叶栅气动性能的实验和数值模拟

为了明确采用高负荷设计及一般设计(低负荷)方法的压气机气动性能和流动转捩的差异,进行了不同攻角下的叶栅吸力面流谱绘制和参数测量实验.并基于实验边界条件,采用γ-θ转捩模型开展数值研究.结果表明:与低负荷叶栅相比,随着攻角的增大,高负荷叶栅主流附面层由附着流变为分离流,尾迹的宽度和损失强度增加,并与角区分离融合为一个"带...     

薄型中空电极振动电解切割TB6钛合金

TB6钛合金由于具有优越的性能,广泛地用于航空航天领域。然而从大余量的TB6钛合金锻铸件毛坯加工成复杂结构的零件,其加工效率低,刀具和机床成本高,造成了极大的浪费。为解决这一问题,提出了一种利用薄型中空电极进行快速大余量去除的电解加工(ECM)方法,即将零件与多余材料切割分离,有望较大程度提高加工效率,降低加工成本。为改善电解加工流场特性,提高加工精度,对电极施加振动,并对薄型中空电极的振动切割进行了建模分析和试验研究。试验结果表明,合适的振动幅值和频率(A=0.05mm,f=50Hz)可以使得各处电解液电导率趋于一致,从而提高加工的精度、稳定性和效率。复杂结构件的成功切割证明了薄型中空电极振动电解切割加工技术具有一定的适用性。     

3D multiphysic simulations of energy field and material process in radial ultrasonic rolling electrochemical micromachining

The radial ultrasonic rolling electrochemical micromachining(RUR-EMM) combined rolling electrochemical micromachining(R-EMM) and ultrasonic vibration was studied in this paper. The fundamental understanding of the machining process especially the interaction between multiphysics in the interelectrode gap(IEG) was investigated and discussed by the finite element method. The multiphysics coupling model including flow field model, Joule heating model, material dissolution model and vibration model ...     

低速风洞均匀吸气地板下阻塞对地板边界层影响的研究

为了研究低速风洞地板下部阻塞对地板上表面边界层的影响以及控制方法，在国防科技大学KD-03低速风洞利用均匀吸气地板系统进行了实验研究。地板下部阻塞对地板上表面主流区的流动产生干扰，并影响边界层的分布和发展，随着地板下部阻塞度的增加，地板上表面边界层的厚度有增加的趋势；在某一阻塞度和吸气系数下，来流速度越大，地板下部的阻塞对主流区流动的影响越小；地板的均匀吸气使边界层的厚度显著降低，也有效减小因地板下部阻塞引起的主流区流动的不均匀性。该实验的研究结论为8m×6m风洞均匀吸气地板系统研制提供了参考。     

Electrochemical machining of complex components of aero-engines: Developments,trends, and technological advances

Because of several advantages, such as no tool wear, independence on the mechanical properties of the material, and high machining efficiency, electrochemical machining (ECM) has become a viable method for machining components in numerous industrial applications, particularly in the manufacture of typical aero-engine components with complex structures fabricated from materials that are difficult to cut. This paper highlights the current developments, new trends, and technological advances of key factors of ECM, such as electrochemical dissolution characteristics of novel difficult to cut materials which are often used in aero-engine, numerical simulation of electrochemical process, design for the complex profile and structure of cathode tool, flow field simulation and design for uniform electrolyte flow, and innovation of electrochemical machining or hybrid methods which reflect the state of the art in academic and industrial research on electrochemical machining in aero-engine manufacturing.     

非定常预处理方法在倾转旋翼飞行器悬停状态气动干扰模拟中的应用

针对倾转旋翼飞行器的多种速度尺度并存的复杂流动问题,发展了能够统一求解同时包含不可压缩流动和可压缩流动的非定常预处理方法和一种考虑了流场物理信息传播方向的预处理远场边界条件。结合适用于倾转旋翼飞行器的复杂外形及大位移问题的非结构混合网格技术和重叠插值技术,建立了倾转旋翼飞行器的数值模拟方法。在此基础上,首先通过悬停算例验证了数值方法的有效性,确定了选择预处理截断参数的原则。然后探究了倾转旋翼飞行器直升机模式悬停状态的尾迹涡结构演化过程,研究了“喷泉效应”和“地面效应”对倾转旋翼气动性能的影响。计算结果表明,旋翼尾迹涡的耗散在不同方位角存在较大差异。“地面效应”抑制了旋翼尾迹的发展,提高了旋翼整个方位角区域的升力系数,而不仅限于机翼上方方位角区域。 “地面效应”作用强于“喷泉效应”作用,使旋翼相对于孤立旋翼拉力系数略微增大了5.26%,但同时整个倾转旋翼飞行器的总的向上的力只有孤立旋翼拉力的82.46%。结论表明预处理方法和预处理远场边界条件能够较好地模拟倾转旋翼飞行器悬停状态的干扰流场,兼顾了数值计算的耗散性和稳定性。气动干扰对倾转旋翼飞行器整体气动性能有重大影响。      

Electrochemical machining on blisk channels with a variable feed rate mode

Electrochemical machining (ECM) is an economical and effective method for blisk manufacturing and includes two steps: channel machining and profile machining. The allowance distribution after the channel machining will directly affect the profile machining. Therefore, to improve the uniformity of allowance distribution in the machining of channels, a method that incorporates a variable feed rate mode is developed. During the machining process, the feed rates are dynamically changed according to the needs of the side gap at the different feed depths. As a result, the side gaps at the different feed depths vary, contributing to a decrease in the allowance difference. In this study, the dissolution processes of a blisk channel are simulated using different feed rates, and prediction profiles are obtained. Based on the prediction profiles, the relationship among the feed rate, feed depth, and side gap is established. Then, the feed rates at different feed depths are adjusted according to the relationship. In addition, contrast experiments are conducted. Compared with blisk channel ECM using a constant feed rate of 1 mm/min, using the variable feed rate decreases the allowance differences in the convex and concave parts by 62.2 % and 67.4 %, respectively. This indicates that using the variable feed rate in the ECM process for a blisk channel is feasible and efficient.     

冲击发散冷却流场结构PIV测量

为了研究冲击发散冷却结构的流场特性,设计了一典型冲击发散冷却结构,采用粒子图像测速仪(PIV)对其流场特性进行了研究.研究发现,在冲击板与发散孔板间,气流的流动状态很复杂,在各个方向上均形成大量的涡,且涡的形式和强度均随吹风比的变化而变化.在发散气膜侧,随着吹风比的增大,由发散孔流出的冷却气流会逐渐穿透主流,从而使得冷却气膜层愈来愈不稳定,脱离壁面;而在发散孔出口与主流方向垂直的位置会形成一对旋转方向相反的肾形涡,且涡的位置随吹风比的增大而移向主流区域.      

发动机起动/关机过程中喷管侧向载荷试验

为了获得大面积比喷管在发动机起动/关机过程中的侧向载荷,搭建了喷管侧向载荷冷流试验系统,通过测量应变管感知的喷管侧向载荷和通过加速度传感器感知的喷管振动载荷,分析发动机起动/关机过程中喷管侧向载荷的变化规律。试验表明:试验喷管在发动机起动/关机过程中均存在3个峰值侧向载荷,起动过程中分别对应着初始正激波向稳定自由激波分离的转变过程、自由激波分离向受限激波分离的转变过程以及分离激波结构处于“末端振动状态”,关机过程则恰好相反,而且关机过程相对起动过程的峰值侧向载荷发生压比存在一定的迟滞效应;喷管壁面的周向应变对侧向载荷非常敏感,而壁面轴向应变却基本不受喷管侧向载荷的影响;喷管侧向载荷是激励喷管振动的主导因素,并在试验喷管发生“末端振动效应”时,振动加速度峰值达到最大为80g。      

液氧甲烷发动机台阶型冷却通道的耦合传热特性

为了研究液氧甲烷发动机再生冷却通道中跨临界甲烷的流动和传热特性,以及冷却通道较大幅度的突扩突缩对冷却效果的影响,采用整场直接耦合的方法对推力室三维耦合传热进行了数值模拟,考虑了燃气的非平衡流动.通过计算得到了推力室三维温度场和流场.计算结果表明：由于喉部截面附近存在较强的二次流,燃气侧壁面温度的最大值出现在喉部上游.由于突扩突缩处存在较强的旋涡运动,冷却剂的湍流强度增强,冷却剂侧表面传热系数显著提高,燃气侧壁面温度出现局部极小值,同时也产生了较大的局部损失.由于铜内衬热阻比镍外套热阻小得多,从燃烧室进入的大部分热量在冷却通道底面和侧面被冷却剂吸收.冷却通道底面的温度和热流密度沿程变化比顶面更剧烈.     

添加络合剂电解加工小孔的实验研究

本文通过向电解液中加入络合剂与常规电解加工进行了侧面间隙、加工效率的对比实验,对添加络合剂的加工机理以及实验结果进一步分析。实验分析表明,和常规电解加工小孔相比,添加络合剂使得加工间隙内气、液、固三相流场更趋于气、液两相流场,改善了流场分布的均匀性,从而使得加工过程中侧面间隙变小,加工精度和加工效率得到提高。