| With the development of aerospace industry,the complexity of modern engine blade structure and the special requirements of materials,the requirements for processing technology are also increasing.Electrochemical machining eliminates the interference of the mechanical properties of metal materials and expands the use range of metal materials.Because the tool does not directly contact the workpiece during the machining process,there are no defects such as residual stress,flashing burrs,etc.In addition,the tool and the workpiece will not be in direct contact during the processing,which greatly reduces the cost of the tool,and is very suitable for the processing of complex processing and mass production of blades.Based on the above reasons,the process method of electrochemical machining has been developed urgently.In this paper,the process parameters of superalloy blades are studied,and a certain model of aeroengine blades is taken as an example to study the superalloy blades electrochemical processing technology.The main research contents of this paper are as follows:1.Introduced the basic principles and characteristics of electrochemical machining,and the theoretical basis of electrochemical machining.According to the characteristics of the processed specimens and combined with the working characteristics of the vertical single-head ECM machine tool,a geometric model for processing leaf pots and leaf backs was established to provide a theoretical model for subsequent ECM experiments of blades.2.Optimization test of electrochemical machining process parameters.Using the plate structure to carry out experimental research,the influence of electrochemical machining process parameters on the maximum feed rate and surface roughness of the anode was explored.Based on this,an orthogonal experiment was designed,and the processing results were analyzed by the gray correlation analysis method,and the optimal processing parameter combination was determined.3.Numerical simulation research on the blade forming process of a vertical single-head ECM machine tool.During the blade forming process,the changes of the flow field under the two different processing sequences of the leaf pot and the leaf back are analyzed,and the electric field at different processing depths during the processing is simulated.4.Experimental research on electrochemical machining of blades.Combining the characteristics of the blades of the processed specimens,the results of numerical simulation and the working characteristics of the vertical single-head ECM machine tool,the tooling and related fixtures for this ECM blade test were designed.A theoretical analysis of the gap control in the machining process was carried out,and a set of gap control system devices used in this experiment were built.In order to verify the rationality of the experimental tooling and process parameters,a certain type of blade was used as the processing object on a vertical single-head electrochemical machining machine developed by itself,and the blade electrochemical machining experiment was carried out. |
