Abstract
Good heat dissipation performance of aero-engine an effectively improve the service performance and service life of aero-engine. Therefore, this paper studies the machining method of cooling holes of high-temperature existent material GH 4169 for aero-engine innovatively puts forward the mask electrochemical machining method of cooling holes and explores the entrance morphology and taper formation law of the hole structure of high-temperature resistant material GH 4169. The mathematical model of anode dissolution of cooling holes in ECM is established, and the influence of voltage and electrolyte flow rate on cooling holes in ECM is analyzed. Compared with the mask-less electrochemical machining, the inlet radius of cooling holes in mask electrochemical machining is reduced by about 16.0% and the taper is reduced by 52.8% under the same machining parameters, which indicates that the electrochemical machining efficiency of mask is higher and the machining accuracy is better. Experiments show that the diameter of the mask structure improves the accuracy of the inlet profile of the cooling hole in the ECM. The diameter of the mask increases from 2 mm to 2.8 mm, and the inlet radius of the cooling hole increased from 1.257 mm to 1.451 mm When the diameter of the mask is 2.2 mm, the taper of the cooling hole decreased by 53.4%. The improvement effect is best, and the thickness of the mask has little influence on the forming accuracy of the cooling hole.
Highlights
Turbine blade is an important part of the aero-engine, and its structure and process in technology directly affect the performance of the engine
In order to improve the power of the turbine engine, it is necessary to ensure that the turbine works in the high-pressure gas above 1 MPa and the high-temperature environment of 1000 degrees Celsius, which will greatly reduce the service life of turbine blades and lead to the failure of the combustion chamber
Turbine blades are mainly made of high temperature resistant alloys, such asGH 4169
Summary
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. Machining cooling holes on high temperature resistant alloys can effectively improve the performance and service life of aero-engine [2]. EDM and laser machining are hot machining, which inevitably leads to the formation of hot recast layers and micro cracks on the metal surface These methods will affect the machining accuracy, stability and working performance of cooling hole. In order to study the effectiveness of this method, this paper establishes a mask electrochemical machining simulation model to explore the influence of the mask structure on the current density distribution on the surface of the workpiece, the distribution of electric field lines in the processing area and the distribution of current density on the workpiece surface with time were simulated and analyzed under the conditions of no mask and mask. Materials 2022, 15, 1973 surface with time were simulated and analyzed under the conditions of no mask and mask
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