Flow Field Design And Experimental Research Of Electrochemical Machining Ofaxial Blade On Diffuser

Integral component represented by integral diffuser is one of the core parts of aeroengine, it will be widely applied in aeroengine because of its good performance and high reliability. While the structure of integral component is complex, the material is difficult to machining, aviation integral component machining is one of the hot issues in the field of advanced manufacturing technology. Electrochemical machining(ECM) has obvious advantages in the field of integral component machining and becomes the main method of manufacturing integral component because of mechanical properties independence, high machining efficiency, tool cathode without loss, no machining deformation of workpiece.In this paper, for machining the axial blade of diffuser, structures of cathode and fixture were designed, flow field design and simulation were carried out. Experiments of electrochemical machining of axial blade on diffuser were carried out, the detail tasks are as follows:(1)According to the structure characteristics of axial blade, a simple and effective machining scheme was developed, the structure and size design of tool cathode with a insulated cavity were carried out. Ultimately the scheme of cathode with electrode body, built-in insulated cavity, flaky electrode was confirmed, the fixture was designed according to the workpiece.(2)The flow method of axial blade ECM was determined. According to the structure characteristics of combined cathode, two models of the flow field were built, flow field simulation was carried out by using flow field software of finite element method. Improvement measures of flow field were put forward based on the results of simulation, then simulation calculation of the improved flow field was carried out. After analysing flow field vector diagram of processing face,the inlet of electrolyte from the side of blade basin and back was better with an optimized electrolyte outlet. Finally the combined cathode was produced by adopted the better flow field.(3) Experimental research on axial blade ECM was carried out. The effects of electrolyte pressure,votlage and machining speed paraments are analysed by basic experiment. The basic experiment of ECM current control was carried out and the base current curve was put foward, then speed adjustment experiment was done. Finally machining current change was stable within the base current range through speed regulation, the consistency of processing current change was improved.(4) The three factors orthogonal experiments of voltage, machining speed, electrolyte pressure of axial blade ECM were carried out to get optimized parameters. Voltage 20 V, machining speed 2 mm/min, electrolyte pressure 1.4Mpa was confirmed as optimized parameters.blade back taper is 0.99°. blade basin taper is 1.18°,roughness value of blade is 1.387μm. Different speed machining tests are carried out, machining speed is 3mm / min, machining efficiency is high, blade back taper is 1.08°, blade basin taper is 1.16°.