The Electric Field Simulation And Experimental Study On The Method Of Electrode Radial Feeding In Blisk ECM

Turbine blisk is one of the important components of aeroengine，it is very difficult to processbecause of its complicated structure, twisted blade profile. Electrochemical machining (ECM) is anon-traditional machining technology based on electrochemical anodic dissolution in electrolyte.Because of no mechanical cutting force, no residual stress, no tool wear, and high efficiency, ECMbecomes the main method to manufacture aircraft engine blisk.This paper focus on processing blisk tunnels with small and uniform finishing allowance, whichstretches along the following several aspects.(1)A mathematical model based on electric field that describe the processing was developed,which is used to simulated the processing with finite element method. Then the study on forming rulewas investigated. It shows that the side gap of blisk tunnel processed by non-insulation cathode is toolarge,which result in large allowance difference; the side gap of blisk tunnel processed by insulationcathode was more uniform than by non-insulation cathode. Finally experiment was carried out byusing side insulation cathode and non-insulaton cathode. The results shows that the allowancedifference of leaf basin decreased from4.41mm to2.58mm and leaf black decreased from3.76mm to2.53mm.(2) Optimized the cathode from two aspects:. Optimized the cathode by improving the sidecontour line. The method from ‘face’ to ‘line’ is utilized to optimized the cathode. The relationshipwas established between the two-dimension section line and the side contour line by switchthree-dimension model into two-dimension model.The experiments indicate that allowance differenceof blisk tunnels processed by optimized cathode was effectively reduced.Ⅱ. Optimize the insulationarea of the side insulation cathode. Optimize the cathode by exposed part of the insulation area toincrease the corrosion in part area of blisk tunnels with large allowance,which was based onallowance distributed and the analysis of the relationship between bare area and corssion. Finally theexperiments were carried out. The results shows that it was effectively reduced allowance differenceby optimized cathode.