整体叶盘电解加工阴极修正方法与试验

Experimental Study on Cathode Modification for Electrochemical Machining of Blisk

电解加工是航空发动机整体叶盘制造的主要技术之一,阴极修正是该加工技术的重要环节。为了提升阴极修正精度,提出了恒采样点空间法向修正方法。该方法将阴极型面设计、加工误差分析、工具阴极修正统一至阳极采样点空间法向的一维坐标系中,将复杂的三维曲面修正简化为离散的一维修正,消除了加工误差与修正量的错位。以某整体叶盘为例,在自行研制的整体叶盘型面电解加工机床上开展工具阴极修正试验,采用三坐标测量机对修正前后的加工样件进行检测,经过一次修正,叶片电解加工精度由0.25mm提高至0.04mm,试验结果表明该阴极修正方法合理有效,具有较强的可行性。

Electrochemical machining （ECM） is one of the important technologies in production of aeroengine blisk.The cathode modification is an important part of the processing technology.In order to improve the modification precision of cathode,a new method based on normal direction of constant sampling points is presented.The 1-D coordinate system along the normal direction of sampling points is established.The basic cathode surface,machining error and correction value are calculated in the coordinate system.The position deviation of machining error and correction value is eliminated by using the new method.In order to test the validity of the cathode modification method,experimental investigations of blisk processing are carried out by using a self-designed blisk ECM system.The machining samples are detected by the three-coordinate measuring machine.After one modification of cathode,the accuracy of ECM blade is increased from 0.25 mm to 0.04 mm.Experimental results verify the feasibility and effectiveness of the new cathode modification method.