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。

Design and Experiment of Electrolyte Flow Mode in Electrochemical Machining of Blisk

Electrochemical machining (ECM) is an important processing technology in aerospace industry to produce blisks. The stability of the flow field is a critical factor which affects the ECM process accuracy and the surface quality of the blades. This paper analyzes the insufficient fluid of the traditional flow mode in electrochemical machining of blisks. A new electrolyte flow mode, the "3D complex flow mode", is proposed to machine blisks. There are three electrolyte inlets in this flow mode, which allow flows into the leading edge of the blade, the root of the concave blade and the root of the convex blade. The electrolyte outlet is near the exhaust edge of the blade. The flow mode is analyzed by the finite element method. The results demonstrate that flow field stability is enhanced with this flow mode. An evaluation of the flow state in the processing area indicates that this mode is able to meet the requirements of ECM. Experimental investigations are carried out in order to evaluate the feasibility of the flow mode. The results show that machining efficiency is improved significantly with this flow mode. The processing experiment for the section part of a blisk is carried out by using the 3D complex flow mode. The test specimens exhibit better processing repeatability and surface quality.