Research And Application Of Pulse Voltage And Electrode Vibration Coupling Electrochemical Machining Technology

Electrochemical machining(ECM)technology is one of the key manufacturing technology to machine the core components of aero-engine,such as blades and blisks.However,with the development of the aviation industry,the structural complexity and precision requirement of the new aero-engine parts were continuous rising.In order to improve the ECM accuracy and leveling ability,the research on pulse voltage and electrode vibration coupling technology was carried out.The transporting of electrolysis products and the processing current were analyzed;the effect of machining parameters on ECM precision and leveling ability were revealed.Finally,the experimental investigation of ECM aero-engine blade with pulse voltage and electrode vibration coupling were carried out.The main contents of this paper are as follows:(1)The experimental platform of ECM with pulse voltage and electrode vibration coupling was built.The electrode mechanical vibration device and machining gap visualization fixture were designed.The control system of pulse voltage and electrode vibration coupling with IGBT was improved.The detection system which to pick up the processing data,such as current waveform,vibration waveform and the gap video image,was established by current sensor,eddy current displacement sensor,using high-speed camera and recorder.(2)Put forward the ECM method of pulse voltage and electrode vibration front coupling.Based on the analysis of ECM experiments of DC and electrode vibration coupling,the phenomenon of current waveform occurred before vibration waveform was found.the ECM method of pulse voltage and electrode vibration front coupling which based on the crest of machining current waveform was put forward.The rationality of the new machining method was validated by contrast experiments.(3)Experimental investigation on ECM of pulse voltage and electrode vibration front coupling was carried out.In order to evaluate the rationality of the new method,the ultimate capacity comparison experiments,such as feed speed,machining gap and leveling ability,were carried out.The experimental results showed that the new method had better performance.The processing experiments for die forging aero-engine turbine blades were carried out by using pulse voltage and electrode vibration front coupling method.The test specimen has better precision and surface quality.