Cathode Design Of Electrochemical Machining With Variable Internal Cavity Profile Blisk

The blisk is the core component of an aero engine,which has the advantages of light weight,long service life,less gas loss,large thrust-to-weight ratio,and stable and reliable operation.However,the blisk has narrow passage between blades,thin blades,complex and twisted profiles,and always use titanium alloy and other high-strength materials.All these make the traditional mechanical cutting method has many defects,such as low efficiency,processing difficulties and so on.EMC has a series of advantages,including good surface quality,no mechanical cutting force,no tool cathode loss and no restrictions on cutting materials.It has been widely used in the field of blisk processing,and has gradually become one of the core technologies in blisk manufacturing.In order to solve the problem of machining large twisted and variable cross-section blisk in the field of EMC,this topic focuses on the design of cathode for variable profile EMC tool,and the main aim is to produce the blank of blisk blade with more uniform allowance distribution.The research contents mainly are as follows:(1)Based on the synthesis and simulation of the planar shape variable rigid body mechanism,the relationships between the design contour,the target contour and the average contour are studied.The variable cathode connecting rod was designed by using the average contour,and the approximate relationship between the cathode connecting rod and each design contour is verified by motion simulation analysis.(2)Based on the method of machining cascade passage,the structure of Cathode is designed.The uniformity of the blank margin distribution of the blisk is verified by comparing the motion trajectory of the inner cavity of the connecting rod with the target blade.Under the requirements of ensuring the material of the completely eroded cascade passage and the flatness of the impeller,the overall structure of the tool cathode is designed and revised.The three-dimensional model of the blisk is simulated by tracing the trajectory of the tool cathode.Finally,by comparing the residual distribution of the blade blank processed by sleeve machining method and radial forming machining method,the feasibility of this machining method is verified.(3)Based on the working characteristics of the tool cathode,the three-dimensional flow field model of the inner electrolyte was established.In addition,we use the Fluent software to simulate the flow pattern of the electrolyte during EMC.The Velocity Vector Nephogram of tool cathode in the initial,intermediate and final states shows that the flow of electrolyte during machining meets the requirements of EMC.Figure[66]Table[2]Reference[80]...