Electrode design using revolving entity extraction for high-efficiency electric discharge machining of integral shrouded blisk

The integral shrouded blisk provides better performance with minimum weight,but its semi-open structure presents problems for its production.Manufacturing processes of these components require a removal of about 70%-90%of material from their blanks.Multi-axis electrical discharge machining(EDM)is commonly used for these processes,but its poor efficiency cannot meet the requirements of mass production.Strong flushing assisted high-current discharge is able to improve the machining efficiency.In this paper,this method was applied to manufacture the integral shrouded blisk.An electrode design method was proposed.Taking the largest revolving entity inside the flow channel as the base geometry,this laminated arc-shaped hollow electrode meets the requirements such as high pressure flushing,tool wear compensation,and easy to be made.A 4-axis linkage machining tool path with planetary motion was proposed.Taking an integral guide vane ring as an example,it has been experimentally verified that the time consumption for each channel using this method was reduced to a half of the ordinary EDM method,while the finished surface quality remains same.

The coupling effect of slow-rate mechanical motion on the confined etching process in electrochemical mechanical micromachining

By introducing the mechanical motion into the confined etchant layer technique(CELT), we have developed a promising ultraprecision machining method, termed as electrochemical mechanical micromachining(ECMM), for producing both regular and irregular three dimensional(3 D) microstructures. It was found that there was a dramatic coupling effect between the confined etching process and the slow-rate mechanical motion because of the concentration distribution of electrogenerated etchant caused by the latter. In this article, the coupling effect was investigated systemically by comparing the etchant diffusion, etching depths and profiles in the non-confined and confined machining modes. A two-dimensional(2 D) numerical simulation model was proposed to analyze the diffusion variations during the ECMM process, which is well verified by the machining experiments. The results showed that, in the confined machining mode, both the machining resolution and the perpendicularity tolerance of side faces were improved effectively. Furthermore, the theoretical modeling and numerical simulations were proved valuable to optimize the technical parameters of the ECMM process.