Basic Research On Rotate-Print Electrochemical Machining Of Surface Convex On Revolving Parts

The machining technology of the thin-wall revolving work-piece with complex structure and special material has been the key parts in aero-engine manufacturing. There are some problems such as the deformation of thin-wall parts, low machining efficiency and high tool costs in conventional machining of the thin-wall parts. However, Electrochemical machining method has become a primary means of solving these problems, because it has many advantages such as no stress machined surface, non-thermal deformation, high efficientcy, no restrictions in material strength and hardness, etc. For the convex structure on the revolving work-piece, the technology of Rotate-Print Electrochemical Machining is used to study the law of its forming process in this paper.To study the forming regulation of convex on anode, a finite element model based on electric field that describe the Rotate-Print Electrochemical Machining processing was developed. The analytical program was compiled based on the APDL language provided by ANSYS.The simulation were carried out by using traditional non-insulation cathode and partial insulation cathode. And the forming process of high convex was simulated. Through these processes, the calculations of machining results were carried out, and the forming regulation of convex was explored, which can be used to supervise the following experiments proceeding.The experiments were carried out by using non-insulation cathode and partial insulation cathode. The experimental result showed that using partial insulation cathode can obviously reduce the stray corrosion on the super alloys convex surface. The contour of convex was improved and the profile was clearer. And the experiments of high convex were carried out. The experiments results and simulation results were basically identical.The electrochemical machining properties of super alloys were studied, then a method that in the anode passivation coating the surface properties of the metal sacrificial layer was put forward and a corresponding comparison experiment was launched. The experiment results showed that: the anode surface passivation properties of the metal coating sacrificial layer approach almost completely inhibited the top surface of the convex stray corrosion, the machined convex clearly sharper contours, achieved very good results.