Nickel-based superalloys are widely employed in modern aircraft engines because of their excellent material characteristics, particularly in the fabrication of film cooling holes. However, the high machining requireme...Nickel-based superalloys are widely employed in modern aircraft engines because of their excellent material characteristics, particularly in the fabrication of film cooling holes. However, the high machining requirement of a large number of film cooling holes can be extremely challenging. The hybrid machining technique of tube electrode high-speed electrochemical discharge drilling (TEHECDD) has been considered as a promising method for the production of film cooling holes. Compared with any single machining process, this hybrid technique requires the removal of more complex machining by-products, including debris produced in the electrical discharge machining process and hydroxide and bubbles generated in the electrochemical machining process. These by-products significantly affect the machining efficiency and surface quality of the machined products. In this study, tube electrodes in different inner diameters are designed and fabricated, and the effects of inner diameter on the machining efficiency and surface quality of TEHECDD are investigated. The results show that larger inner diameters could effectively improve the flushing condition and facilitate the removal of machining by-products. Therefore, higher material removal efficiency, surface quality, and electrode wear rate could be achieved by increasing the inner diameter of the tube electrode. (C) 2015 The Authors. Production and hosting by Elsevier Ltd. on behalf of Chinese Society of Aeronautics and Astronautics.展开更多
基金the financial support provided by the National Natural Science Foundation of China (No. 51475237)the National High-Tech Research and Development Program of China (No. 2013AA040101)+1 种基金the Program for New Century Excellent Talents in University (No. NCET-12-0627) of Chinathe Funding of Jiangsu Innovation Program for Graduate Education (No. KYLX_0232) of China
文摘Nickel-based superalloys are widely employed in modern aircraft engines because of their excellent material characteristics, particularly in the fabrication of film cooling holes. However, the high machining requirement of a large number of film cooling holes can be extremely challenging. The hybrid machining technique of tube electrode high-speed electrochemical discharge drilling (TEHECDD) has been considered as a promising method for the production of film cooling holes. Compared with any single machining process, this hybrid technique requires the removal of more complex machining by-products, including debris produced in the electrical discharge machining process and hydroxide and bubbles generated in the electrochemical machining process. These by-products significantly affect the machining efficiency and surface quality of the machined products. In this study, tube electrodes in different inner diameters are designed and fabricated, and the effects of inner diameter on the machining efficiency and surface quality of TEHECDD are investigated. The results show that larger inner diameters could effectively improve the flushing condition and facilitate the removal of machining by-products. Therefore, higher material removal efficiency, surface quality, and electrode wear rate could be achieved by increasing the inner diameter of the tube electrode. (C) 2015 The Authors. Production and hosting by Elsevier Ltd. on behalf of Chinese Society of Aeronautics and Astronautics.
