涡轮钻具叶片电解加工流场设计及优化

Flow Field Design and Optimization of Turbine Drill Blade Using Electrolytic Machining

为了提升叶片性能,涡轮钻具叶片设计愈加复杂,传统加工工艺已不适于加工制造涡轮钻具叶片。为此,提出使用电解加工技术加工涡轮钻具叶片,并应用数值模拟方法对影响电解加工精度的电解液流场进行仿真分析。模拟仿真了电解液在理想化流道模型、叶片阴极流道模型以及近轮廓流道模型中的流场分布。研究结果表明:用叶片阴极模型和近轮廓模型代替传统的理想化模型,也可更好地模拟实际加工流场;改变电解液入流角的大小可以改善传统的理想化模型,可以更好地模拟实际加工流场;改变电解液入流角的方向可以改善入口流线紊乱情况,但效果并不明显,也不能使电解液均匀分布;增加出口导流段可以使电解液分布更加均匀,改善入口流线紊乱状况;叶盆阴极流场使用竖直导流、叶背阴极流场使用相切导流可以获得更好的流场分布效果;使用近轮廓模型作为电解加工流道,可以获得最优的电解液流场分布,但是此流道模型需要预先粗加工阳极工件,成本较高。研究结果可为涡轮钻具叶片的电解加工提供理论指导。

To improve the performance of the blade,the design of the turbine drill blade is more and more complicated.And the traditional machining process is no longer suitable for processing the turbine drill blade.To address the problem,the electrolytic processing technology is proposed to process and manufacture the turbine drilling blade.The numerical simulation method is used to simulate the electrolyte flow field which affects the precision of electrolytic machining.Simulations are conducted on the flow field distribution of the electrolyte in the idealized flow path model,the cathode blade flow path model and the near-contour flow path model.The results show that the blade cathode model and the near contour model are better alternatives for traditional idealized model.Changing the direction of the electrolyte inflow angle can improve the traditional idealized model and better simulate the actual flow field,and it can also improve the disturbance of the inlet flow line,but the effect is insufficient,and cannot evenly distribute the electrolyte.Addition of the outlet diversion section can make the electrolysis more uniform and reduce the inlet flow disturbance.Better flow field distribution could be obtained with the vertical diversion for the cathode flow field of the blade concave and the tangential diversion for the cathode flow field of the blade back.Taking the near contour model as the electrolytic machining flow path can obtain the optimal flow field distribution of the electrolyte.But costly rough machining of the anode work piece in advance is required.The study could provide theoretical guidance for the electrolytic machining of turbine drill blades.