Simulation Analysis and Process Evaluation of Cooling Hole Forming Precision in Mask Assisted Electrochemical Machining Based on GH4169

Abstract

Good heat dissipation performance of aero-engine an effectively improve the service performance and service life of aero-engine. Therefore, this paper studies the machining method of cooling holes of high-temperature existent material GH 4169 for aero-engine innovatively puts forward the mask electrochemical machining method of cooling holes and explores the entrance morphology and taper formation law of the hole structure of high-temperature resistant material GH 4169. The mathematical model of anode dissolution of cooling holes in ECM is established, and the influence of voltage and electrolyte flow rate on cooling holes in ECM is analyzed. Compared with the mask-less electrochemical machining, the inlet radius of cooling holes in mask electrochemical machining is reduced by about 16.0% and the taper is reduced by 52.8% under the same machining parameters, which indicates that the electrochemical machining efficiency of mask is higher and the machining accuracy is better. Experiments show that the diameter of the mask structure improves the accuracy of the inlet profile of the cooling hole in the ECM. The diameter of the mask increases from 2 mm to 2.8 mm, and the inlet radius of the cooling hole increased from 1.257 mm to 1.451 mm When the diameter of the mask is 2.2 mm, the taper of the cooling hole decreased by 53.4%. The improvement effect is best, and the thickness of the mask has little influence on the forming accuracy of the cooling hole.

Anodic Dissolution Characteristics of GH4169 Alloy in NaNO3 Solutions by Roll-Print Mask Electrochemical Machining Using the Linear Cathode

“…Huang et al [ 17 ] successfully processed high-precision micro-structures on the surface of nickel-based alloy on ECM of nanosecond pulse. Through-mask electrochemical micromachining (TMEMM) is one of the variants of ECM, which is a machining method that uses an insulating material with a customized pattern on the surface as a mask to attach to the surface of the anode workpiece to limit its processing area [ 18 , 19 , 20 ]. It has the advantages of cold processing, flexible solvent, no tool loss and mass manufacturing of TMEMM, which can effectively alleviate the problems of serious stray corrosion and poor localization in the process of conventional electrochemical machining methods.…”

An Investigation of the Efficient–Precise Continuous Electrochemical Grinding Process of Ti–6Al–4V

“…In the process of ECG, the contribution of mechanical and electrochemical energy fields in material removal can be regulated by adjusting parameters, such as the applied voltage and the feed rate. Therefore, the process of ECG can obtain a bigger material removal rate (MRR) than mechanical grinding (MG) and be more precise than electrochemical machining (ECM) [11,12]; it is an ideal technology for the efficient-precise machining of difficult-to-machine materials that are easy to passivate.…”

“…In the process of ECG, the contribution of mechanical and ele chemical energy fields in material removal can be regulated by adjusting parameters, as the applied voltage and the feed rate. Therefore, the process of ECG can obtain a bi material removal rate (MRR) than mechanical grinding (MG) and be more precise electrochemical machining (ECM) [11,12]; it is an ideal technology for the efficient-pr machining of difficult-to-machine materials that are easy to passivate. For the last decades, considerable studies on the ECG process have been condu A. Hascalik [2] performed a precise ECG process on the Ti-6Al-4V surface after elect discharge machining (EDM), applying low voltages in the range of 2-8 V, and a de free machined surface with a low surface roughness of 0.06 µm was obtained.…”