Abstract
Blades are key components in modern aero engines. Their leading and trailing edges are extremely difficult to machine using electrochemical machining (ECM) because of their small thickness and radius of curvature and their marginal location. Traditional ECM of blades requires gaps between the convex part cathode and concave part cathode at the leading and trailing edges to allow passage of electrolyte. The presence of these gaps may lead to large variations in electric field intensity at the end of the machining process as the leading and trailing edges are forming. This paper proposes a new design of cross-structural cathodes to decrease the dynamic variation of the electric field at marginal locations. A mathematical model of material removal is established, taking account principally of the electric field factor. The forming process of the leading edge is simulated, and changes in electric field intensity during the final stages of the process are analyzed. The simulation results show that the maximum fluctuation in the electric field intensity at the leading edge is 62.42% when a conventional cathode is used, but only 30.51% with cross-structural cathodes. Experiments are conducted to compare the performance of conventional and cross-structural cathodes. The results show that, in comparison with conventional cathodes, the use of cross-structural cathodes reduces variations in machining current in the forming stage of margin profiles and leads to more accurate repeatability of the process.
Similar content being viewed by others
References
Rajurkar KP, Levy G, Malshe A, Sundaram MM, McGeough A, Hu X, Resnick R, De Silva A (2006) Micro and nano machining by electro-physical and chemical processes. CIRP Ann Manuf Technol 55:643–666
McGeough JA (1974) Principles of electrochemical machining. Chapman & Hall, London
Klocke F, Zeis M, Harst S, Klink A, Veselovac D, Baumgärtner M (2013) Modeling and simulation of the electrochemical machining (ECM) material removal process for the manufacture of aero engine components. Proc CIRP 8:265–270
Klocke F, Zeis M, Klink A (2015) Interdisciplinary modelling of the electrochemical machining process for engine blades. CIRP Ann Manuf Technol 64:217–220
Fujisawa T, Inaba K, Yamamoto M, Kato D (2008) Multiphysics simulation of electrochemical machining process for three-dimensional compressor blade. J Fluids Eng 130(8):081602-1–081602-8
Kozak J (2013) The computer simulation of electrochemical sha** processes. IAENG Trans Eng Technol 170:95107
Liu WD, Ao SS, Li Y, Zhao CF, Luo Z, Li Q, Luo T (2016) Elimination of the over cut from a repaired turbine blade tip post-machined by electrochemical machining. J Mater Process Technol 231:27–37
Qu NS, Xu ZY (2013) Improving machining accuracy of electrochemical machining blade by optimization of cathode feeding directions. Int J Adv Manuf Technol 68(5–8):1565–1572
Zhu D, Zhu Di XZY, Xu Q, Liu J (2010) Investigation on the flow field of W-shape electrolyte flow mode in electrochemical machining. J Appl Electrochem 41:525–532
Zhu D, Zhu Di XZY (2012) Optimal design of the sheet cathode using W-shaped electrolyte flow mode in ECM. Int J Adv Manuf Technol 62:147–156
Jain VK, Yogindra PG, Murugan S (1987) Prediction of anode profile in ECBD and ECD operations. Int J Mach Tools Manuf 27:113–134
Reddy MS, Jain VK, Lal GK (1988) Tool design for ECM: correction factor method. Trans ASME J Eng Ind 110:111–118
Jain VK, Pandey PC (1981) Tooling design for ECM: a finite element approach. Trans ASME J Eng Industry 103:183–191
Jain VK, Pandey PC (1980) Finite elements approach to the two dimensional analysis of electro chemical machining. Precis Eng 2:23–28
Kozak J (2001) Computer simulation system for electrochemical sha**. J Mater Process Technol 109:354–359
Kozak J, Chuchro M, Ruszaj A, Karbowski K (2000) The computer aided simulation of electrochemical process with universal spherical electrodes when machining sculptured surfaces. J Mater Process Technol 107:283–287
Shenoy RV, Datta M, Romankiw LT (1996) Investigation of island formation during through-mask electrochemical micromachining. J Electrochem Soc 143:2305–2309
Kozak J, Rajurkar KP, Makkar Y (2004) Study of pulse electrochemical micromachining. J Manuf Process 6(1):7–14
Collett DE, Hewson-Browne RC, Windle DW (1970) A complex variable approach to electrochemical machining problems. J Eng Math 4:29–37
Li DL, Zhu D, Li HS (2011) Microstructure of electrochemical micromachining using inert metal mask. Int J Adv Manuf Technol 55:189–194
Thorpe JF, Zerkle RD (1969) Analytic determination of the equilibrium electrode gap in electrochemical machining. Int J Mach Tool Des Res 9:131–144
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zhu, D., Zhao, J., Zhang, R. et al. Electrochemical machining of blades with cross-structural cathodes at leading/trailing edges. Int J Adv Manuf Technol 93, 3221–3228 (2017). https://doi.org/10.1007/s00170-017-0737-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-0737-8