Optimization of flow field in electrochemical trepanning of integral cascades (Ti6Al4V)

Lei, Gaopan; Zhu, Daiyin; Li, Jiabao

doi:10.1016/j.cja.2021.04.005

Cited by 6 publications

(2 citation statements)

References 20 publications

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“…In the same year, Liu et al controlled the flow direction of the electrolyte in the machining area by changing the type of flow channel inside the tool electrode, which can significantly reduce stray corrosion and improve the surface processing quality of TB6 titanium alloy [22]. In 2021, Lei et al proposed an edge electrolyte supply mode and optimized the structure of the insulating sleeve, which effectively improved the machining accuracy and machining quality of the overall blade cascade (Ti6Al4V) processed by electrochemical trepanning [23]. Although changing the flow field mode has many advantages, it requires complex tooling.…”

Section: Introductionmentioning

confidence: 99%

Simulation and Experiment Research on Liquid Channel of Diffuser Blade by Electrochemical Machining

Xu¹,

Tao²,

Ren³

et al. 2021

Preprint

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Aiming to solve the problems of the low electrolyte flow rate at leading edge and trailing edge and poor uniformity of the end clearance flow field during the electrochemical machining (ECM) of diffuser blades, a gap flow field simulation model was established by designing three liquid-increasing channels at the leading edge and the trailing edge of the cathode. The simulation results indicate that the liquid-increasing hole channel (LIHC) with an outlet area S of 1.5 mm2 and a distance L from channel center to edge point of 3.2 mm achieves optimal performance. In addition, the experiment results show that the optimized cathode with liquid-increasing hole channel (LIHC) significantly improves the machining efficiency, accuracy and surface quality. Specifically, the feed speed increased from 0.25 mm/min to 0.43 mm/min, the taper decreased from 4.02° to 2.45°, the surface roughness value of blade back reduced from 1.146 µm to 0.802 µm. Moreoever, the roughness of blade basin decreased from 0.961 µm to 0.708 µm, and the roughness of hub reduced from 0.179 µm to 0.119 µm. The results prove the effectiveness of the proposed method, and can be used for ECM of other complex structures with poor flow field uniformity.

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Section: Introductionmentioning

confidence: 99%

Simulation and Experiment Research on Liquid Channel of Diffuser Blade by Electrochemical Machining

Xu¹,

Tao²,

Ren³

et al. 2021

Preprint

View full text Add to dashboard Cite

show abstract

“…10,11 There are many methods based on ECM available for manufacturing blade components, including numerical control ECM, [12][13][14] profile ECM, [15][16][17] and electrochemical trepanning. 18,19 Numerical control ECM and profile ECM are generally used for cascade channel premachining and integral blade profile finishing respectively. On the other hand, electrochemical trepanning involves processing an offset profile inside the anode according to the profile z E-mail: xujinkai2000@163.com; renwanfei2020@163.com of the cathode, and thereby creating a desired shape.…”

mentioning

confidence: 99%

Research on Multi-physics Field Coupling Dynamic Process in Forward Flow Electrochemical Trepanning Blades

Tao¹,

Xu²,

Ren³

et al. 2022

J. Electrochem. Soc.

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In this work, a multi-physics field coupling model based on electric field, gas-liquid two-phase flow field ,and temperature field of forward flow electrochemical trepanning (FFECT) blades was established, and the distribution law of hydrogen bubble volume fraction, electrolyte temperature, and electrolyte conductivity in the machining gap was obtained. Based on the simulation results, the time-varying process of electrolyte flow velocity distribution was divided into three stages according to the change in machining gap corresponding to different blade machining heights H, and the effects of the machining voltage U and the cathode feed rate v on the side gap Δs and the end gap Δe were investigated. The simulation analysis and experimental results show that both side gap and end gap increase as machining voltage increases but decrease with the increase in cathode feed rate. The model predictions are in good agreement with the experimental results, and the maximum errors of side gap and end gap are 10.6% and 17.7%, respectively. In addition, the effects of machining voltage and cathode feed rate on the surface quality were studied experimentally. Results reveal that surface roughness can be reduced by appropriately decreasing the machining voltage and increasing the cathode feed rate.

show abstract

Simulation and experiment research on liquid channel of diffuser blade by electrochemical machining

Tao

Ren

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Aiming to solve the problems of the low electrolyte flow rate at leading edge and trailing edge and poor uniformity of the end clearance flow field during the electrochemical machining (ECM) of diffuser blades, a gap flow field simulation model was established by designing three liquid-increasing channels at the leading edge and the trailing edge of the cathode. The simulation results indicate that the liquid-increasing hole channel (LIHC) with an outlet area S of 1.5 mm 2 and a distance L from channel center to edge point of 3.2 mm achieves optimal performance. In addition, the experiment results show that the optimized cathode with liquid-increasing hole channel (LIHC) significantly improves the machining efficiency, accuracy and surface quality. Specifically, the feed speed increased from 0.25 mm/min to 0.43 mm/min, the taper decreased from 4.02° to 2.45°, the surface roughness value of blade back reduced from 1.146 µm to 0.802 µm. Moreoever, the roughness of blade basin decreased from 0.961 µm to 0.708 µm, and the roughness of hub reduced from 0.179 µm to 0.119 µm. The results prove the effectiveness of the proposed method, and can be used for ECM of other complex structures with poor flow field uniformity.

show abstract

Optimization of flow field in electrochemical trepanning of integral cascades (Ti6Al4V)

Cited by 6 publications

References 20 publications

Simulation and Experiment Research on Liquid Channel of Diffuser Blade by Electrochemical Machining

Simulation and Experiment Research on Liquid Channel of Diffuser Blade by Electrochemical Machining

Research on Multi-physics Field Coupling Dynamic Process in Forward Flow Electrochemical Trepanning Blades

Simulation and experiment research on liquid channel of diffuser blade by electrochemical machining

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