叶盘通道径向电解加工的流场设计及试验

Flow Field Design and Experimental Investigation of Radial Electrochemical Machining of Blisk Channels

合理的流场设计是实施电解加工的必要前提.为实现叶盘通道的全方位电解加工,采用径向电解加工方法对某型整体叶盘进行研究.首先,设计了可控对称式电解液流场;然后,建立了流场的有限元模型,并利用有限元法对流动方式进行了仿真分析;最后,为验证流场设计的合理性,开展了叶盘通道电解加工试验,试验结果显示,与传统流动方式相比,采用可控对称式流场,叶盘轮毂的表面粗糙度从2.450μm降低至0.154μm,轮毂的加工重复精度在0.07mm以内,叶盆、叶背的重复精度在0.17mm以内.这一结果表明,流场设计合理,有利于提高轮毂的加工质量,可获得较好的加工稳定性及一致性.

Rational design of a flow field is a necessary precondition for the implementation of electrochemical machi- ning. In order to implement the electrochemical machining of blisk channels in a full range, a radial feeding tech- nique was applied to the electrochemical machining of a type of blisk. In the investigation, first, a new controllable symmetric flow field of electrolyte was designed. Then, a finite element model of the flow field was constructed to simulate the electrolyte flow. Finally, some electrochemical machining experiments were carried out to verify the ra- tionality of the designed flow field. The results show that, after the application of the controllable symmetric flow field, the surface roughness of the blisk wheel hub decreases from 2. 450 ~m to 0. 154 p^m, the repeat accuracy of wheel hub is less than 0.07mm, and the repeat accuracies of concave and convex airfoils are both less than 0.17ram, which means that the new flow field is well designed and is effective in improving the machining quality as well as the machining stability and consistency of wheel hub.