整体叶盘是新一代航空发动机的核心部件，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，与传统套料电解加工流场方式相比，浸液式套料电解加工间隙内叶片进排气边缘流速达到24m/s，叶片边缘处的低流速点较少，流场更加均匀，利于改善套料电解加工稳定性。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。选择GH4169G材料开展浸液式及传统冲刷式套料电解加工对比试验，试验结果表明，浸液式加工稳定性较高，工具进给速度由0.55mm/min提升至0.8mm/min，叶型余量更小，叶盘的效率和精度显著提升。该方式还可以应用于航空航天发动机中机匣、扩压器等其它复杂型面零部件的高效稳定制造。
Blisk is the core component of a new generation aero engine, and electrochemical machining is one of its main manu-facturing technologies. Aiming at the problem of short circuit in the inlet and exhaust edge of blade in the traditional ECM of monolithic blade disc nesting, a method of immersion electrochemical trepanning is proposed. The flow channel model of submerged nesting ECM is established, and the dynamic simulation of flow field is carried out. The simulation results show that compared with the traditional nesting ECM flow field, the inlet and exhaust edge flow velocity of the blade in the dip nesting ECM gap reaches 24m/s, there are fewer low flow velocity points at the blade edge, and the flow field is more uniform, which is conducive to improving the stability of nesting ECM. A closed electrolyte tank struc-ture is designed to form a closed electrolyte aggregation pool in the ECM area to realize immersion ECM. GH4169G material is selected to carry out the comparative test of immersion and traditional washing sleeve electrochemical ma-chining. The test results showed that the immersion machining had higher stability, the tool feed speed is increased from 0.55mm/min to 0.8mm/min, the blade profile margin is smaller, and the efficiency and accuracy of the blisk are significantly improved. This method can also be applied to the efficient and stable manufacturing of other complex parts such as casings and diffusers in aerospace engines.
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