Electrochemical machining with independent electrolyte supply at blade leading/trailing edge

Abstract

The blade is a key component of aero engines. In traditional blade electrochemical machining (ECM) processes, the electrolyte is simultaneously supplied to the concave and convex parts. To improve flow field uniformity at marginal areas of the blade, a new blade flow mode with an independent electrolyte supply at the leading and trailing edges is proposed here. Flow field simulations of the entire blade ECM process are carried out. The results show that in comparison with conventional flow field modes, electrolyte distribution in this new flow field mode is more uniform and the change in velocity is smaller along the flow path. In addition, the size and pressure of the liquid inlets at the leading and trailing edges were optimized, with optimal height and pressure values of 3 mm and 0.9 MPa determined, respectively. The results of experimental investigations proved that the new flow mode proposed here was reasonable, and the surface roughness and contour accuracy of the leading and trailing edges were significantly enhanced.