Electrochemical cutting of mortise-tenon joint structure by rotary tube electrode with helically distributed jet-flow holes

In aero-engines,mortise-tenon joint structures are often used to connect the blades to the turbine disk.The disadvantages associated with conventional manufacturing techniques mean that a low-cost,high-efficiency,and high-quality nickel-based mortise-tenon joint structure is an urgent requirement in the field of aviation engineering.Electrochemical cutting is a potential machining method for manufacturing these parts,as there is no tool degradation in the cutting process and high-quality surfaces can be obtained.To realize the electrochemical cutting of a mortise-tenon joint structure,a method using a tube electrode with helically distributed jet-flow holes on the side-wall is proposed.During feeding,the tube electrode rotates along its central axis.Flow field simulations show that the rotational speed of the tube electrode determines the direct spraying time of the high-speed electrolyte ejected from the jet-flow holes to the machining area,while the elec-trolyte pressure determines the flow rate of the electrolyte and the velocity of the electrolyte ejected from the jet-flow holes.The machining results using the proposed method are verified experimen-tally,and the machining parameters are optimized.Finally,mortise and tenon samples are success-fully machined using 20 mm thick Inconel 718 alloy with a feeding rate of 5 μm/s.