基于Realizable k-ε模型的叶盘通道电解加工多场耦合分析

张聚臣; 李世成; 刘洋; 李兴林

doi:10.7527/S1000-6893.2021.25670

航空学报 >

2022 , Vol. 43 >Issue 4: 525670 - 525670

DOI: https://doi.org/10.7527/S1000-6893.2021.25670

论文

基于Realizable k-ε模型的叶盘通道电解加工多场耦合分析

张聚臣 ,
李世成 ,
刘洋 ,
李兴林

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1. 合肥工业大学机械工程学院, 合肥 230009;
2. 南京航空航天大学机电学院, 南京 210016

收稿日期: 2021-04-13

修回日期: 2021-05-09

网络出版日期: 2021-12-01

基金资助

安徽省自然科学基金（2008085QE250）；国家博士后科学基金（2018M642246）；江苏省自然科学基金（BK20190419）

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Multi-physical field analysis of tunnel ECM employed Realizable k-ε model

ZHANG Juchen ,
LI Shicheng ,
LIU Yang ,
LI Xinglin

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1. College of Mechanical Engineering, Hefei University of Technology, Hefei 230009, China;
2. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics & Astronautics, Nanjing 210016, China

Received date: 2021-04-13

Revised date: 2021-05-09

Online published: 2021-12-01

Supported by

Natural Science Foundation of Anhui Province (2008085QE250); China Postdoctoral Science Foundation (2018M642246); Natural Science Foundation of Jiangsu Province (BK20190419)

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摘要

叶盘通道电解加工（ECM）是决定整体叶盘电解加工成形精度的关键工序，其加工间隙不规则、建模困难。基于Realizable k-ε模型建立叶盘通道电解加工的气液两相流模型，根据参数传递关系建立多物理场耦合模型，分析加工间隙内电解液温度、氢气体积分数、电导率等重要参数的分布规律。仿真结果显示电解液在侧面间隙出现涡流现象，使该区域氢气堆积、温度上升，影响工件的成形表面质量，并导致该处的材料蚀除量减小，该结果在试验中得到证实。试验与仿真得出的工件轮廓形状变化趋势一致，试验与仿真获得的端面平衡间隙尺寸分别为0.26、0.33 mm，仿真的相对误差（27%）明显小于经典公式的相对误差（73%）。因此，模型可较为准确地模拟叶盘通道电解加工成形过程，反映各参数对工件成形的影响过程。

关键词： 电解加工; 叶盘通道; 多物理场耦合仿真; 平衡间隙; 加工质量

本文引用格式

张聚臣 , 李世成 , 刘洋 , 李兴林 . 基于Realizable k-ε模型的叶盘通道电解加工多场耦合分析[J]. 航空学报, 2022 , 43(4) : 525670 -525670 . DOI: 10.7527/S1000-6893.2021.25670

Abstract

Tunnel ECM is a key process that affects the machining accuracy of blisk ECM of which the forming model is difficult to establish. In this paper, a two-phase flow model based on Realizable k-ε model is established, and a multi-physical field coupling model is built based on the parameter relationship of tunnel ECM. The parameter distribution of temperature, hydrogen volume fraction and electrolyte conductivity in the process and their influence on the surface quality were analyzed by simulation, which shows the vortex region in the side gap increases hydrogen volume and electrolyte temperature. This phenomenon affects the surface quality, decreases the material removal rate, and is verified by the experiments. The balance gaps obtained by simulation and experiment are 0.33 mm and 0.26 mm. Thus the relative error of simulation (27%) is much lower than that of theoretical calculation (73%). Therefore, the model is consistent with the forming process and reflects the influence of machining parameters on the workpiece forming of blisk tunnel ECM.

Key words： ECM; tunnel; multi-physical field coupling simulation; balance gap; machining quality

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