整体叶盘型面电解加工阴极“C”形加强筋结构优化设计

Optimal Design of Cathode C-shaped Reinforced Structure in Blisk ECM

电解加工整体叶盘时,由于叶栅通道狭窄,阴极工具必须设计成薄片结构,因此减少工具阴极在高速、高压电解液环境中的变形显得尤为重要。采用单向流固耦合方法分析了三维复合流场下2.5 mm等厚度薄片阴极的变形,分析结果表明该阴极变形量过大,无法满足要求。设计了"C"形加强筋结构,提出了一种加强筋厚度优化方法,获得了最优加强筋厚度,并对设计优化后的阴极进行变形仿真,仿真结果表明:叶背阴极变形量从0.052 mm减少到了0.003 7 mm,叶盆阴极变形量从0.061 mm减少到了0.007 4 mm,阴极变形量显著减小。

In the blisk ECM process, because the channel between two blades is narrow, the cathode must be thin-sheet structure, there fore it is especially important to decrease the cathode deformation in the electrolyte under certain pressure. One way fluid-structure interaction method is used to analyze the deformation of the thin-sheet cathode with 2.5 mm cross-section in the 3D complex flow field. As the cathode deformation is so large that it cannot meet the requirements, C-shaped reinforced structure, whose thinkness will be optimized by an optimization method, is designed. Then the deformation simulation of the new cathode is carried out. The result shows that, the convex cathode deformation is reduced from 0.0,52 mm to 0.0037 mm, and the concave cathode deformation is reduced from 0.061 mm to 0.00？4 ram. The cathode deformation is greatly reduced.