Study On Electrolytic Milling Technology Of Nickel-based Superalloy

Nickel-based superalloys have three major characteristics: excellent high temperature strength,good thermal stability and strong fatigue.This material can work under high temperature oxidizing gas and gas corrosion conditions of600℃～1000℃.It can withstand complex stress and is widely used in heatresistant thin-walled parts such as impellers and blades of gas turbines,especially for aerospace engines.However,ordinary mechanical processing methods an d other traditional processing methods such as electric discharge machining and electrolytic machining are difficult to meet the existing requirements for the use of high-temperature alloy materials.For this reason,it is of great significance to explore and master new processing methods of superalloys.Electrolytic milling processing integrates the advantages of electrochemical machining and mechanical milling.The whole process uses the principle of electrochemical anode to dissolve metal to process the material.Electrolytic milling uses the method of trajectory milling to perform non-contact processing of complex profiles through a single cathode.The whole machining process has the characteristics of no tool wear and no internal stress and burrs on the workpiece.This article conducts research and analysis from the following aspects:First,the cathode shape was designed and optimized by 3D modeling,flow field analysis and electric field analysis.Then,through orthogonal experiments,the process parameters were optimized,and the influence law of temperature,voltage,spindle speed and other factors on the feed rate in electrolytic milling was obtained,and the optimized process parameters were obtained.Under the conditions of obtaining optimized parameters and electrolytic cathode,a machining experiment was carried out on an integral impeller,and the G code was edited according to the principle of cathode side edge milling and imported into the machine tool for processing.Finally,compared with tra ditional milling processing methods,the advantages of electrochemical composite machining are analyzed in terms of processing time,processing accuracy,processing cost,and processing difficulty.