整体叶盘浸液式套料电解加工流场仿真与试验
收稿日期: 2024-10-12
修回日期: 2024-10-31
录用日期: 2024-12-27
网络出版日期: 2025-03-28
基金资助
国家自然科学基金(52275435);国家自然科学基金创新研究群体(51921003)
Flow field simulation and experiment on immersion electrochemical trepanning of blisk
Received date: 2024-10-12
Revised date: 2024-10-31
Accepted date: 2024-12-27
Online published: 2025-03-28
Supported by
National Natural Science Foundation of China(52275435);National Natural Science Foundation of China for Creative Research Groups(51921003)
整体叶盘是新一代航空发动机的核心部件之一，电解加工是其主要制造技术之一。针对传统整体叶盘套料电解加工中叶片进排气边易发生短路问题，提出浸液式套料电解加工方法，建立浸液式套料电解加工流道模型，开展了流场动力学仿真研究。仿真结果表明，与传统冲刷式套料电解加工流动方式相比，浸液式套料电解加工间隙内叶片进排气边缘流速达到24 m/s，叶片边缘处的低流速点较少，流场更加均匀。设计封闭式电解液槽体结构，在电解加工区域内形成封闭的电解液聚集池，实现了整体叶盘浸液式电解加工。开展了浸液式及传统冲刷式GH4169G整体叶盘套料电解加工对比试验，结果表明，浸液式加工稳定性较高，工具进给速度由0.55 mm/min提升至0.8 mm/min，叶盘加工效率和表面质量显著提升。该方式还可以应用于航空航天发动机中机匣、扩压器等其他复杂型面零部件的高效稳定制造。
陈文亮 , 张钦洪 , 朱栋 , 王福平 . 整体叶盘浸液式套料电解加工流场仿真与试验[J]. 航空学报, 2025 , 46(12) : 431396 -431396 . DOI: 10.7527/S1000-6893.2024.31396
Blisk （bladed-disk） is one of the core components in the new generation aeroengine. And electrochemical machining （ECM） is one of the main manufacturing technologies for blisk. To address the problem of short circuit at the leading edge and trailing edge of the blade， a new immersed flow mode is proposed in electrochemical trepanning （ECTr） for blisk. The flow channel model of the new flow mode was established， and the dynamic simulation of the flow field was carried out. The simulation results showed， compared with the traditional flushing flow mode， the submerged ECM approach achieves a blade-edge flow velocity of 24 m/s in the immersed flow mode， reduces low electrolyte velocity points at the blade edge， and enhances the overall flow field unity. A closed electrolyte reservoir was designed to form a closed electrolyte aggregation pool to realize the immersed flow mode. Corresponding experiments were carried out in two flow modes for blisk made of GH4169G material. The results showed that the feed rate of the tool increased from 0.55 mm/min to 0.8 mm/min in the immersed flow mode compared with that in the flushing flow mode， and the machining stability， machining efficiency and surface quality of the blisk was significantly improved. This new flow mode can also be applied to manufacture casings， diffusers， and other complicated components in aerospace engines.
| [1] | 黄春峰. 现代航空发动机整体叶盘及其制造技术［J］. 航空制造技术， 2006（4）： 94-100. |
| HUANG C F. Modern aeroengine integral blisk and its manufacturing technology［J］. Aeronautical Manufacturing Technology， 2006（4）： 94-100 （in Chinese）. | |
| [2] | 史耀耀， 段继豪， 张军锋， 等. 整体叶盘制造工艺技术综述［J］. 航空制造技术， 2012（3）： 26-31. |
| SHI Y Y， DUAN J H， ZHANG J F， et al. Blisk disc manufacturing process technology［J］. Aeronautical Manufacturing Technology， 2012（3）： 26-31 （in Chinese）. | |
| [3] | 徐家文， 云乃彰， 王建业. 电化学加工技术： 原理、工艺及应用［M］. 北京： 国防工业出版社， 2008： 3-5. |
| XU J W， YUN N Z， WANG J Y. Electrochemical machining technique： principle， technology and application［M］. Beijing： National Defense Industry Press， 2008： 3-5 （in Chinese）. | |
| [4] | LIN J H， ZHU D， HU X Y. Flow field design and experimental investigation of the electrochemical trepanning of a diffuser with a liquid-increasing seam［J］. The International Journal of Advanced Manufacturing Technology， 2021， 112（9）： 2533-2545. |
| [5] | KLINK A， HEIDEMANNS L， ROMMES B. Study of the electrolyte flow at narrow openings during electrochemical machining?［J］. CIRP Annals， 2020， 69（1）： 157-160. |
| [6] | WANG H， ZHU D， LIU J. Improving the accuracy of the blade leading/trailing edges by electrochemical machining with tangential feeding［J］. CIRP Annals， 2019， 68（1）： 165-168. |
| [7] | SAWICKI J， PACZKOWSKI T. Effect of the hydrodynamic conditions of electrolyte flow on critical states in electrochemical machining［J］. EPJ Web of Conferences， 2015， 92： 02078. |
| [8] | PATEL D S， SHARMA V， JAIN V K， et al. Sustainable electrochemical micromachining using atomized electrolyte flushing［J］. Journal of The Electrochemical Society， 2021， 168（4）： 043504. |
| [9] | LIU Y， QU N. Improvements to machining surface quality by controlling the flow direction of electrolyte during electrochemical sinking and milling of titanium alloy［J］. SCIENCE CHINA Technological Sciences， 2020， 63（12）： 2698-2708. |
| [10] | HU X， ZHU D， LI J， et al. Flow field research on electrochemical machining with gas film insulation［J］. Journal of Materials Processing Technology， 2019， 267： 247-256. |
| [11] | WANG K， SHEN Q， HE B. Localized electrochemical deburring of cross hole using gelatinous electrolyte［J］. Materials and Manufacturing Processes， 2016， 31（13）： 1749-1754. |
| [12] | GHOSHAL B， BHATTACHARYYA B. Influence of vibration on micro-tool fabrication by electrochemical machining［J］. International Journal of Machine Tools and Manufacture， 2013， 64： 49-59. |
| [13] | LIU J， HUI L， JIA D， et al. An electrochemical machining method for aero-engine blades based on four-directional synchronous feeding of cathode tools［J］. Chinese Journal of Aeronautics， 2023， 36（9）： 380-391. |
| [14] | 张聚臣， 李世成， 刘洋， 等. 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. |
| ZHANG J C， LI S C， LIU Y， et al. Multi-physical field analysis of tunnel ECM employed Realizable k-ε model［J］. Acta Aeronautica et Astronautica Sinica， 2022， 43（4）： 525670 （in Chinese）. | |
| [15] | FAN Z， WANG T， ZHONG L. The mechanism of improving machining accuracy of ECM by magnetic field［J］. Journal of Materials Processing Technology， 2004， 149（1-3）： 409-413. |
| [16] | LI X C， MING P M， ZHANG X M， et al. Kerosene-submerged horizontal jet electrochemical machining with high localization［J］. Journal of the Electrochemical Society， 2019， 166（13）： E453. |
| [17] | DE SILVA A， ALTENA H， MCGEOUGH J. Influence of electrolyte concentration on copying accuracy of precision-ECM?［J］. CIRP Annals， 2003， 52（1）： 165-168. |
| [18] | BURGER M， KOLL L， WERNER E A， et al. Electrochemical machining characteristics and resulting surface quality of the nickel-base single-crystalline material LEK94?［J］. Journal of Manufacturing Processes， 2012， 14（1）： 62-70. |
| [19] | KLOCKE F， ZEIS M， KLINK A. Interdisciplinary modelling of the electrochemical machining process for engine blades［J］. CIRP Annals， 2015， 64（1）： 217-220. |
| [20] | NEKHOROSHEV M V， PRONICHEV N D， SMIRNOV G V. Creating an electronic reference and information database for computer-aided ECM design［J］. IOP Conference Series： Materials Science and Engineering， 2018， 302（1）： 012049. |
| [21] | LU J M， RIEDL G， KINIGER B， et al. Three-dimensional tool design for steady-state electrochemical machining by continuous adjoint-based shape optimization［J］. Chemical Engineering Science， 2014， 106（1）： 198-210. |
| [22] | IGNAT L， PELLETIER D， ILINCA F. A universal formulation of two-equation models for adaptive computation of turbulent flows［J］. Computer Methods in Applied Mechanics and Engineering， 2000， 189（4）： 1119-1139. |
/
| 〈 |
|
〉 |
CJA