Electrochemical Machining of Blisk Channels with Progressive-Pressure Electrolyte Flow

Qu, Ningsong; Hu, Yan; Zhu, Daiyin; Xu, Zhengyang

doi:10.1080/10426914.2014.892974

Cited by 46 publications

(17 citation statements)

References 20 publications

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“…, n; σx i (j) and σx i (l) are the standard deviation of x i (j) and x i (l), respectively. Then calculating the eigenvalue and eigenvector by solving the characteristic Equation (8). The eigenvalue λ k can be obtained,…”

Section: Multi-objective Optimization Methodsmentioning

confidence: 99%

“…Then dynamic simulation analysis of the designed disk milling tool was carried out to optimize the structure of tool by comparing the change of stress, total deformation main cutting force. From the study of Qu et al [8], progressive-pressure electrolyte flow was employed to improve efficiency and accuracy of radial electrochemical machining of blisk channels. Flow field simulation indicated that the progressive-pressure flow provided a high electrolyte flow rate in the inter-electrode gap allowed a high cathode feed rate without shortcut.…”

Section: Introductionmentioning

confidence: 99%

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Multi-Objective Parameter Optimization for Disc Milling Process of Titanium Alloy Blisk Channels

Shi

2019

Symmetry

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The blisk has been widely used in modern high performance aero-engines of high thrust-weight ratio. Disc milling process provides a reliable way to improve the efficiency of the blisk milling. The process parameters of disc milling have crucial effects on the milling efficiency and physical property of blisk. In this paper, material removal rate, cutter life and thickness of residual stress layer are regarded as optimization targets the key process parameters such as spindle speed, cutting depth and feed speed are optimized. Based on the grey relational analysis, the multi-objective optimization problem is transformed into a single objective optimization problem. At the same time, the problem of non-symmetry influence of key process parameters on optimization targets can be solved. And the influence weight of material removal rate, cutter life and thickness of residual stress layer on the grey relational grade (GRG) are calculated according to principal component analysis. The second order prediction model of GRA is developed by response surface method. On the basis of verifying the accuracy of the model, the influence mechanism of the process parameters coupling on the gray correlation degree is analyzed the optimal process parameter combination is obtained as spindle speed with 81.92 rpm, cutting depth with 5.88 mm and feed rate with 66.0823 mm/min. The experimental research show that the optimal process parameter combination can effectively improve the material removal rate and cutter life and reduce the thickness of residual stress layer.

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Section: Multi-objective Optimization Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Multi-Objective Parameter Optimization for Disc Milling Process of Titanium Alloy Blisk Channels

Shi

2019

Symmetry

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“…Many experimental results have shown that turbulent flow is necessary for the stability of the ECM process 27 . Here, the three-dimensional electrolyte flow field is described using the standard κ–ε turbulence model 28 .…”

Section: Flow-field Analysismentioning

confidence: 99%

“…According to the theory of ECM, the inter-electrode gap Δ can be expressed as 27 , 29 where η is the current efficiency, ω is the volume electrochemical equivalent, κ 0 is the electrolytic conductivity, U is the applied voltage, δE is the polarization potential and v f is the feed rate.…”

Section: Flow-field Analysismentioning

confidence: 99%

Investigation of material removal in inner-jet electrochemical grinding of GH4169 alloy

Niu

Zhang

et al. 2017

Sci Rep

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Electrochemical grinding (ECG) is a low-cost and highly efficient process for application to difficult-to-machine materials. In this process, the electrolyte supply mode directly affects machining stability and efficiency. This paper proposes a flow channel structure for an abrasive tool to be used for inner-jet ECG of GH4169 alloy. The tool is based on a dead-end tube with electrolyte outlet holes located in the sidewall. The diameter and number of outlet holes are determined through numerical simulation with the aim of achieving uniform electrolyte flow in the inter-electrode gap. Experiments show that the maximum feed rate and material removal rate are both improved by increasing the diamond grain size, applied voltage, electrolyte temperature and pressure. For a machining depth of 3 mm in a single pass, a feed rate of 2.4 mm min−1 is achieved experimentally. At this feed rate and machining depth, a sample is produced along a feed path under computer numerical control, with the feed direction changing four times. Inner-jet ECG with the proposed abrasive tool shows good efficiency and flexibility for processing hard-to-cut metals with a large removal depth.

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“…Qu et al carried out the study on Monel 400 using PCM. Study shows that rolling direction affects etch rate [7]. For the first time Bruzzone and Reverberi introduced simulation in PCM.…”

Section: Introductionmentioning

confidence: 99%

Investigation on Surface Roughness of Inconel 718 in Photochemical Machining

Misal¹,

Sadaiah

2017

Advances in Materials Science and Engineering

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The present work is focused on estimating the optimal machining parameters required for photochemical machining (PCM) of an Inconel 718 and effects of these parameters on surface topology. An experimental analysis was carried out to identify optimal values of parameters using ferric chloride (FeCl3) as an etchant. The parameters considered in this analysis are concentration of etchant, etching time, and etchant temperature. The experimental analysis shows that etching performance as well as surface topology improved by appropriate selection of etching process parameters. Temperature of the etchant found to be dominant parameter in the PCM of Inconel 718 for surface roughness. At optimal etching conditions, surface roughness was found to be 0.201 μm.

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Electrochemical Machining of Blisk Channels with Progressive-Pressure Electrolyte Flow

Cited by 46 publications

References 20 publications

Multi-Objective Parameter Optimization for Disc Milling Process of Titanium Alloy Blisk Channels

Multi-Objective Parameter Optimization for Disc Milling Process of Titanium Alloy Blisk Channels

Investigation of material removal in inner-jet electrochemical grinding of GH4169 alloy

Investigation on Surface Roughness of Inconel 718 in Photochemical Machining

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