| Gas elbow is an important component in thrust chamber of rocket engine, and its structure is similar to variable cross-section bending tube. The gas elbow is welded together by half pipe inside and outside in order to ensure structure quality and strength. The workpiece material is superalloy, which has high strength, high hardness, and poor mechanical processing performance. The traditional mechanical machining also is difficult to complete tasks even if using cemented carbide cutting tools, ceramic cutting tools and PCBN cutting tools. Therefore, this subject takes advantage of ECM to process the gas elbow, and design a set of special cathode jig according to processing requirement.According to processing requirement, simulate the electrochemical machining process of the gas elbow based on COMSOL Mutiphysics simulation software, and iterative refined cathode surface by the simulation results. Simulate the flow field of half pipe inside and outside based on ANSYS Fluent, and designed cathode structure which meet the technological requirement according to the analysis and test results. Based on ANSYS Workbench platform, finite element analysis and parametric design were carried out on the cathode jig and the optimal design of cathode shape and size were competed.To set the process system based on the horizontal electrochemical machining machine tool DJK3235, and researched the processing experiment by two kinds of cathodes designed by equal gap and by actual electric field distribution. In addition, the experiment also proved the feasibility of sealing equipment. |
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