Machining Parameter Optimization of Aero-Engine Blade in Electrochemical Machining Based on BP Neural Network

Abstract

Because the process of blade in electrochemical machining(EMC) can be effected by many factors, such as blade shapes, machining electrical field, electrolyte fluid field and anode electrochemical dissolution, different ECM machining parameters maybe result in great affections on blade machining accuracy. Regard some type of aero-engine blade as research object, five main machining parameters, applied voltage, initial machining gap, cathode feed rate, electrolyte temperature and pressure difference between electrolyte inlet and outlet, have been evaluated and optimized based on BP neural network technique. From 3125 possible machining parameter combinations, 657 optimized parameter combinations are discovered. To verify the validity of the optimized ECM parameter combination, a serial of machining experiments have been conducted on an industrial scale ECM machine, and the experiment results demonstrates that the optimized ECM parameter combination not only can satisfy the manufacturing requirements of blade fully but has excellent ECM process stability.

Optimization of Processing Parameters in ECM of Die Tool Steel Using Nanofluid by Multiobjective Genetic Algorithm

“…It is more appropriate one to machine a nonmachinable hard materials such as HCHCr die tool steel, AISI 202 Austenitic stainless steel, and superalloys [ 3 , 4 ]. The parameters of the ECM influencing the objectives of MRR and surface roughness are applied voltage, tool feed rate, and electrolyte discharge rate [ 5 – 7 ]. The electrolyte flows through the interelectrode gap (IEG) and the machining reaction is very appreciable when the value of IEG is small [ 8 , 9 ].…”

Design of an electrochemical micromachining machine

“…This board is also interfaced with the direct pulse width modulation (PWM) amplifiers: the outputs of this board are the PWM control signals that switch the power semiconductors in the drive.  ACC36UK: this analogue input board is made of 16 analogue inputs which have a 16bit resolution. Analogue signals can be acquired at a frequency of 1 kHz for all channels and 16 kHz on a single channel.…”

“…This machining technology is being developed to meet the increasing demand driven by progress made in aerospace (aero-engine blades [16] and gas turbine blade cooling system [17]), microelectronics [18], automotive (requirement for smaller fuel injection nozzles holes with complex shape in combustion engines), electronics (miniaturization of components), medical and biomedical fields [19][20][21]. It enables the machining of micro-size features with high accuracy and high aspect ratio in materials with high hardness and stiffness (or in the materials that are very hard to machine conventionally because they are very brittle such as Indium Antimonite (InSb)) [22].…”