Basic Research On Electrochemical Machining Technology Of Large Twist Blade Of Aeroengine

As a key component of aero-engine,the design and manufacturing level of blade directly affects the performance,reliability and service life of engine.Blades are usually characterized by large degree of distortion,thin blade wall and poor rigidity,and difficult material processing,etc.However,in order to ensure engine performance,the accuracy of blade profile is required to be relatively high,so it is difficult for traditional machining methods to achieve the accuracy of blade profile.Electrochemical machining(ecm)is especially suitable for machining aero-engine blades because of its high machining efficiency,no macro cutting force and no loss of tool cathode.However,a certain type of blade involved in this paper has a large degree of distortion,which makes it difficult to control the consistency of electrochemical machining clearance,and the cathode design and correction cycle of the tool is long,so it is difficult to accurately calculate the electrochemical machining clearance,which restricts the further development of electrochemical machining technology for aero-engine blades.In this paper,based on the electrochemical machining scheme analysis of large twisted blade,the fixture and tool cathode were designed,and then the electrochemical machining test of blade was carried out.The cathode profile was optimized according to the test results,and the blade basin and back profile with an average error distribution of 0.1074 mm and 0.1195 mm were finally produced.The research content mainly includes the following aspects:1.Based on the improved particle swarm optimization algorithm,the cathode feeding direction was designed and optimized,and the design software module was developed based on UG software,and the relatively evenly distributed value was obtained,which is conducive to the improvement of machining accuracy.2.Designed the tool cathode based on the equal inflow Angle rule and method,and carried out a series of process tests on the independently developed blade electrochemical machining equipment,optimized the cathode structure and proposed a composite guide section design method,which improved the flow rate and stability of the processing area.3.Based on BP neural network and multi-physical field coupling simulation,the cathode surface optimization module was developed.It can effectively reduce the number of electrochemical machining tests on the blade,improve the efficiency of cathode correction,and comprehensively analyze the electrochemical machining gap,so as to predict the distribution of machining gap,conduct iterative optimization on the cathode surface,and produce the blade specimen meeting the process requirements,which has been used in the production of a certain type of blade.