Abstract
As an effective method of electrochemical machining (ECM), electrochemical trepanning (ECTr) is used in the machining of the outward facing blisks in aero-engines such as the integral blisk and the diffuser. However, as a special type of blisk, the inward facing blisk has dense blades, narrow spaces in the disc and poor tool accessibility. To date the research on the ECTr of the inward facing blisk is lacking. In this study, a cambered cathode structure is proposed for ECTr of the inward facing blade, since this can improve the distribution of the multiphysics coupling fields in the machining gap and result in an improvement in the quality of machining for the inward facing blade. To progress this idea, a multiphysics coupling fields model for ECTr of inward facing blade based on electric field, gas-liquid two-phase flow field and temperature field is established. Then through simulation of the multiphysics coupling fields, the distribution laws for the flow velocity, the current density, the gas bubbles volume fraction, the temperature and the electrolyte conductivity in the machining gap are obtained. Compared with a conventional planar cathode structure, in the transition section, the uniformity of the flow field of a cambered cathode is improved, and the formation time of the blade is shorter, such that the machining quality and efficiency of the inward facing blade is enhanced. Subsequently, a series of ECTr experiments is conducted on the inward facing blade, and the simulation prediction is found to be in good agreement with the experimental results. As a result of using a cambered cathode, the cathode feed rate is increased from 1.6 mm/min to 2.2 mm/min, with the result that the machining efficiency is increased by 37.5 %. The width and surface quality of the blade improved with increase of the feed rate, the width increasing from 11.506 mm to 12.413 mm, and the surface roughness increasing from Ra 1.372 μm to Ra 0.953 μm. Use of a cambered cathode as the inward facing blade is demonstrated, and the feasibility of a novel ECTr method is verified.
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