Cathode design of aero-engine blades in electrochemical machining based on characteristics of electric and electrolyte flow field

Cathode design is a difficult problem must be faced and solved in ECM. We develop a new numerical approach for cathode design by employing a finite element method and this approach has been applied in the cathode design of aero-engine blades in ECM. The mathematic models of the electric filed and electrolyte flow filed distribution in EMC process are described primarily. Then the realization procedure of this approach is presented，in which the effects of electric filed and electrolyte flow filed distribution within the inter-electrode gap domain are concentrated. In order to verify the machining accuracy of the designed cathodes, the experiments are conducted using an industrial scale electrochemical machining system. The experimental results demonstrate that the machined blade have high surface quality and dimensional accuracy which proves the proposed approach for cathode design of aero-engine blades in ECM is applicable and valuable.

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Comparative Analysis of Flow Field in Mixed and Non Mixed Gas Electrochemical Machining for Aero-Engine Turbine Blade Cooling Holes

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.868.166 ◽

2017 ◽

Vol 868 ◽

pp. 166-171

Author(s):

Zhing Yong Li ◽

Xiu Ting Wei ◽

Wen Wen Lu ◽

Qing Wei Cui

Keyword(s):

Flow Field ◽

Flow Velocity ◽

Turbine Blade ◽

Electrochemical Machining ◽

Machining Accuracy ◽

Mixed Gas ◽

Turbine Blade Cooling ◽

Blade Cooling ◽

Vortex Zone ◽

Aero Engine

By the cooling holes in aero-engine turbine blade as the research object, this study focuses on two kinds of ECM methods, which are mix gas added to the nonlinear electrolyte (NaNO3) and non-mixed gas. Mixed and non-mixed gas ECM experiments of turbine blade cooling holes were carried out respectively. The corresponding two-dimensional CAD model of cooling hole was constructed combined with the experimental data and theoretical analysis. Numerical simulation analysis was carried out of the flow field base on the above models by using the fluid dynamics analysis software FLUENT. The influence flow velocity and flow velocity distribution on the machining accuracy and efficiency of ECM were investigated in detail. The vortex zone distribution of gas-NaNO3 mixed phase flow field and single NaNO3 solution flow field was analyzed qualitatively. The simulation results indicated that the flow velocity in the machining gap with mixed gas was significantly higher than the velocity during ECM process for cooling holes. The electrolytic products and heat were washed away completely, the electrolyte can be updated in time. Fluid vortex zone distribution was improved obviously, the flow field distribution became more uniform after mixed gas in ECM process. The machining accuracy and efficiency for cooling holes making may be improved greatly with gas mixed in electrolyte NaNO3.

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The Effects of Normal Gap Distribution on Cathode Design of Aero-Engine Blades in Electrochemical Machining

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.97-101.3583 ◽

2010 ◽

Vol 97-101 ◽

pp. 3583-3586 ◽

Cited By ~ 1

Author(s):

Zhi Yong Li ◽

Hua Ji

Keyword(s):

Design Method ◽

Electrochemical Machining ◽

Difficult Problem ◽

Machining Process ◽

Machining Accuracy ◽

Machining Parameters ◽

Three Dimension ◽

Cathode Design ◽

Aero Engine ◽

Machining Rate

Cathode design is a difficult problem must be faced and solved in electrochemical machining (ECM). In ECM process, various parameters, such as applied voltage, current density, gap distribution, machining rate and electrolyte composition and concentration, can affect ECM machining process and therefore cathode design. Among all these machining parameters, gap distribution is the most vital. Regard some type of aero-engine compressor blade as research object, this paper concentrates on the effects of the normal gap distribution of 2-dimension and 3-dimension on cathode design based on the cathode design method of , moreover the errors between two and three dimension normal gap also can be compared and analyzed in detail. To verify the accuracy of the designed cathode, the machining experiments were conducted on an industrial scale ECM machine and the experimental results demonstrates that the cathode designed utilizing 3-dimension normal gap exhibits more machining accuracy and therefore valuable.

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