Fundamental Process Experiment Study On Electrochemical Machining Cooling Holes Of Nickel-based Superalloy

Nowadays, with t he cont inuous de ve lopme nt, improve me nt and opt imizat io n, electroche mica l mac hining tec hno lo gy has obta ined t he important deve lopme nt and app licat ion in t he fie ld of prec is ion mac hining, especia lly e lectroche mica l machining process by tube electrodes has become t he importa nt processing technology of aircraft engine’s cooling holes machining field. This paper mainly completed the following several aspects of the research:(1) The characteristics of several aircraft engine’s cooling ho les mac hining techno logies were ana lyzed, especia lly, the curre nt situat io n and exist ing proble ms of cooling ho les in electroche mica l mac hining were describes. And the process theories of electrochem ical machining by the tube electrodes were elaborated.(2) Based on the important process factors and the characterist ics of electroche mica l machining by tube e lectrodes, cooling ho le s’ machining test was des igned ma inly fro m the three aspects o f mac hining vo lta ge, electrolyte concentrat ion a nd electrode feed rate. Thro ugh ana lyzing a nd monitor ing the test results, the influe nce of three process factors on the stability, mac hining accuracy and machining effic ie ncy of e lectroche mica l machining coo ling ho les by the t ube electrodes was determined.(3) The fluid ve loc it y fie ld and t urbule nce distr ib ut io n in t he electroche mica l machining area were ana lyzed us ing the C FD software(Fluent). The basic relat io nship between machining vo ltage, electro lyte co ncentrat ion and electrode feed rate with the fluid velocity field and turbulence distribution was discussed.(4) Based on the results of C FD ana lys is, the para meters of the experime nt were adjusted and opt imizat ion e xperime nts were done. Through the ana lys is of results of basic exper ime nts and optimizat io n experime nts, the optima l process parameters were obtained.(5)The influe nce of electro lyte add it ive- sodium citrate on the electroche mica l machining process was researched, and the conc lus io n that ad ding appropriate sod ium c itrate in t he electro lyte can e ffect ive ly improve t he processing s tability, surface qualit y and machi ning precision was found.