Research On Efficient And Prompt Numerical Control Electrochemical Machining Of The Integral Components And Its Application

In new engine of aircraft and rocket, and some key equipment in other industrial fields, integral components have been widely used. Because of the complex structures and hard to cut material features, how to produce those integral components quickly and inexpensively becomes a key problem in the field of advanced machining technology which worldwide researchers are trying to solve, and those high-tech technology becomes a secret in many countries, the know-how about it can not be published. As a new kind of technology, Numerical Controlled Electrochemical Machining (NC-ECM) has some outstanding advantages in machining integral components, especially used for producing some complex integral components. But compared with traditional Electrochemical Machining (ECM), the machining efficiency of NC-ECM is low; on the other hand, compared with NC milling, the preparing time for NC-ECM is long. Both of them restricted the advantages of NC-ECM in produce integral components. In order to shorten the preparing time and raise the machining efficiency, a new designing method of cathode, a new planning method of cathode movement and machining efficiency of NC-ECM have been studied in this dissertation.In order to shorten the designing time for cathode, and reduce the times of trial-and-error, the method of apply Computational Fluid Dynamics (CFD) software to aid designing flow structure of cathode has been studied. The cathode designing method has been successful used for producing integral aircraft shell and opened integral impeller, compared to the existing methods, the time of cathode designing have been reduced by 60%.For the purpose of improving efficiency of NC-ECM, the shaping rule of inter-electrode gap and processs efficiency have been researched. Based on these researches, the shape of inter-electrode gap and the machining efficiency could be analyzed after scatter complex work face into some little planes. In this way, the process of NC-ECM could be optimized, and improve the surface quality and machining efficiency of NC-ECM.As an applied object of above researches, in order to improve the production efficiency of NC precision electrochemical machining opened integral impeller, the methods of cathode designing and NC movement designing have been researched. These incloud the CFD software aided design cathode, design movement trajectory according to the rule surface of offset surface of vane,and developed a mathematical model to design velocities of NC movement. Finally, a test piece of opened integral impeller were produced, the results show that the time of technological designing have been shortened.As another applied object, the high efficiency and rapid respone technologies of NC-ECM in combined electrical machining 3D-flow closed integral impeller have been researched. Because the complex vane surface, narrow and twist channel, 3D-flow closed integral impeller are difficult for machining, we dispart the channel into many parts, than machining those parts with many cathodes, in this way, the designing about profile and movement of cathodes could be simplified. In order to raising the machining efficiency, some craft hole have been drilled in work piece before NC-ECM, and correct the profile of cathode based on analysis of machining efficiency, both of these increased the machining efficiency more than about 320%. In the end, a formal 3D-flow closed integral impeller has been produced, the results show that these technologies could improve the machining efficiency and reduce the prepare time of NC-ECM in combined electrical machining 3D-flow closed integral impeller.