Research On Application Of Precise ECM Technology For Irregular Channel Structures

With the rapid development of modern aviation technology,irregular channel structures are increasingly appearing in the structural design of key components of the new generation aero engines.The structure of abnormity channel parts is more complex,and the use of high-strength steel,high temperature alloys,titanium and other difficult to process materials,most of the processing methods is difficult or even impossible to achieve its high-precision machining.Because of its high machining efficiency,good surface quality,no loss of tool cathode and no mechanical cutting force,electrochemical machining has a good application prospect in the processing of special-shaped channel structural parts.However,there are many influencing factors in ECM,the process parameters are difficult to be controlled precisely,the machining process is not stable enough,and the machining precision is still to be improved,which limits the extensive application of ECM technology.In this paper,based on the theoretical analysis of electrochemical machining of the special-shaped channel structure and the experimental system of the precision ECM,a type of radial diffuser is researched,and a precise electrochemical machining experiment of the shaped channel is carried out.The main research contents are as follows:1.Based on the theory of electrochemical machining,the factors influencing the stability and machining accuracy of electrochemical machining of profiled channels are analyzed.The influence of the cathode vibration on the flow field in the machining gap and the influence of the vibration feed and the pulsed power supply on the electrochemical machining process are studied.It is concluded that the matching can improve the machining atability and the machining precision.2.Aiming at the short-circuit problem of the diffuser,the cathode structure is optimized based on the analysis of the anode forming rule.Based on the theory of fluid dynamics,ANSYS CFX flow field simulation software is used to analyze the influence of electrolyte inlet pressure and outlet pressure on the electrolyte pressure and velocity distribution in the machining gap,which provided the basis for the selection of the electrolyte pressure.3.Based on precision electrochemical system,the influence of process parameters on the stability and precision of electrolytic finishing is analyzed by single factor comparison experiment and parameter optimization experiment,and the combination of process parameters is optimized to meet the engineering application requirements of the high-precision channel.