| Integral Structure of Compact structure, light weight, high strength has become an important technical measure in aerospace engines, and its overall manufacturing has become a hot topic in the world’s advanced manufacturing field, some scholars have studied the organic combination of ECM-EDM. Two steps of diging groove and shaping followed are used in Electrochemical rough Machining. To shorten the working hours of ECM, The scheme of diging groove with shaping simultaneously is proposed in this paper. And then the first thing we have to face with is the asymmetry distributing of flow field in machining gap.In order to solve the problem of irregular distributing of flow field in machining gap for machining the variable cross-section helix cavity of the closed integral structure from its infall to the laryngeal. To find out how to design the distribution, size and shape of these holes based on the initial cathode, to check whether there are any vortexes or cavities in the gap flow field and to optimize the cathode and fixture finally, the simulation for flow field based on COMSOL Multiphysics in different pressure was carried out. The result certificate that the flow field in machining gap is relatively uniform and the electrolyte flow is more adequate in condition of adjusting the holes’distribution in different gaps, making the narrow groove instead of holes partly, and increasing the pressure difference between inlet and outlet of electrolyte (use6mm diameter of fixture holes instead of8mm).To prevent short circuit in the electrochemical machining, we add a set of control valve and pressure gauge used to adjust the pressure on each of both export pipelines of the runner skeleton in this paper. Simulating based on COMSOL on different backpressure conditions was done by changing water hole diameter of the fixture means. The results show that applying the appropriate backpressure can effectively prevent the generation of cavitation. |
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