Study on the Key Technology of Electrochemical Machining Flow Field in Aero-Rotor Blades

With the rapid development of aerospace industry in recent years, the use of aero-rotor engine blades with new special alloy materials and high distortion and thin-walled structure has been paid more and more attention. Aiming at the problems of poor tool accessibility, serious tool loss and easy deformation of blade profile in NC milling technology, electrochemical machining can realize the processing of complex special structure products with advanced materials by means of non-contact electrochemical etching process. However, in the process of electrochemical etching, the flow channel structure of electrochemical machining affects the stability of the distribution of electrochemical etching characteristics in various parts of the machining surface and ultimately acts on the forming quality by controlling the liquid phase mass transfer process in the machining gap. Therefore, reasonable design and optimization of the flow channel is of great significance in the process of electrochemical machining. In this paper, based on the existing traditional vertical single-axis feed machining mode and combined with the traditional side flow processing blade flow characteristics, innovatively proposed two kinds of electrolyte flow schemes under the vertical machining mode; Then, based on the above two flow channel structures and the energy loss characteristics of viscous fluid during liquid phase mass transfer, a mathematical model of liquid phase mass transfer flow field is established, which combines the viscosity loss characteristics of electrolyte, and by introducing a optimized flow channel structure that combined with the characteristics of positive flow and side flow and adjusting the parameters of electrolyte inlet / outlet, the optimal design channel structure and uniform flow field of aero-rotor blades are realized. Finally, the accuracy and rationality of the proposed scheme are verified by electrochemical machining verification test, which lays a research foundation and guarantee for the feasibility and accuracy of vertical electrochemical machining machine tool in aero-rotor blades.