Simulation And Experiments Study Of Leading/trailing Edge With Closed Physical Field In Electrochemical Machining

Blade is of critical importance to aero-engine,whose manufacturing level has directly effect on thrust weight ratio,safety and reliability and decides the flying speed,flexibility and effective load capacity.ECM(Electrochemical Machining)is a main processing method of blade because of its no limitation by mechanical properties of materials,high efficiency,no tool wear,no heat-affected zone and high surface quality.Leading and trailing edges are Indispensable parts of the blade,which play a decisive role in aerodynamic performance.However,because of its complex structure and small radius,it is a difficult and key point in the field of electrolytic processing.In this paper,the following research is carried out on the electrochemical machining of the inlet and exhaust parts of the blade:(1).A multi-physical field coupling simulation model is set up and the research based on model is carried out about the Leading and trailing edges.Re-design the cathodes on the basis of the result of simulation.Deviation between sections of blades machined by redesigned cathode is smaller than that of traditional cathodes.So the model has a positive significance to improving the processing precision.(2).The electric field simulation model is set up and a plate cross-structure cathode is proposed.The relationship between stability of electric and the value of the cross-structure is draw from the result of simulation and experiment.It shows that the appropriate value has a positive effect on the repetition precision of leading/trailing edge rather than large cross value.(3).A flow field structure with four fluid-supply channels is proposed.The velocity distribution in the field near the leading/tailing edge result from four-channel structure is more uniform that of traditional flow field structure.So the four-channel structure is of positive significance to improving the processing stability and repetition precision of leading/trailing edge.(4).The cross cathode structure is used and the factors affecting the multi physical coupling field are considered in the process of cathode design.The experiment result shows that the precision of the blade-basin is within the range of-0.080 mm to-0.0372 mm,and the machining precision of the leading/trailing edge is within the range of-0.0905 mm to-0.0079 mm.