Electrochemical Drilling Of Deep Small Holes In Titanium Alloy With Pulsating Electrolyte Flow

The characteristics of the blade cooling holes in turbine engine, such as small diameter, highaspect ratio, materials difficult to cut, make its process difficult. But, Shaped tube electrochemicaldrilling(STED) has such advantages as good surface integrity, no tool wear, irrelevant to mechanicalproperties, which are suitable for drilling of small hole in titanium. In order to avoid harm to theenvironment by using acid electrolyte, the neutral salt solution is proposed to replace the acidelectrolyte. In order to enhance the removal rate of insoluble products in machining gap, the pulsatingelectrolyte flow is introduced. And the following works have been done:1. The experimental system of STEM of drilling of deep small hole with pulsating electrolyteflow has been designed, including machine body, the electrolyte system, the control system, theelectrode fixture, the power system, ect.2. In the process of electrochemical drilling of deep small holes with constant electrolyte flow,the influence of process parameters including the initial machining gap, tool feed rate, the pressure ofelectrolyte, pulse voltage, and pulse duty ratio, were investigated.3. Experiments are conducted to study the effects of constant electrolyte flow and pulsatingelectrolyte flow on the removal of byproducts.4. In the process of electrochemical drilling of deep small holes with pulsating electrolyte flow,The influence of process parameters of pulsating electrolyte flow on the machining accuracy of deepsmall holes are also studied. And based on the optimized parameters of pulsating electrolyte flow,Experiments are conducted to study the effects of constant electrolyte flow and pulsating electrolyteflow on the machining accuracy of deep small holes.