航空发动机复杂扭曲叶片分步电解加工研究

为实现复杂扭曲叶片在较小间隙下的稳定加工,提出了一种分步式电解加工的工艺方法,建立了复杂扭曲叶片小间隙(0.2 mm)和大间隙下(0.5 mm)扭曲流道的流道模型,采用有限元法进行了流场仿真研究,结果表明增加流道间隙可以解决流道中涡流和流场紊乱的问题。开展了复杂扭曲叶片小间隙连续式加工和分步式加工的试验研究。结果表明,采用小间隙连续式加工,当阴极进给至3.8 mm位置时,在叶片排气边靠近叶根流道扭曲处出现短路打火情况;而采用分步式加工方式能够实现加工的顺利进行。

Research on Noncontinuous Electrochemical Machining for Complex Blades

To improve the stability of electrochemical machining(ECM)for complex twisted blade under small inter-electrode gap,a new method,in which the continuous process is divided into two steps,is proposed.Its twisted flow channel model with a small gap(0.2 mm)and a large gap(0.5 mm)is built and the flow field is simulated.The results show that the disorder of the flow channel can be eliminated by increasing the flow channel gap.The machining conditions in the continuous process and noncontinuous process are designed,and a series of corresponding ECM experiments are carried out.The results show that when the small gap flow channel is used for continuous process,the machining distance is 3.8 mm,and a short-circuit sparking occurs at the twisted place of the blade trailing edge.However,the noncontinuous process is used to guarantee the stability of complex twisted blade machining.