Abstract
The blade is a key component of aero engines. In traditional blade electrochemical machining (ECM) processes, the electrolyte is simultaneously supplied to the concave and convex parts. To improve flow field uniformity at marginal areas of the blade, a new blade flow mode with an independent electrolyte supply at the leading and trailing edges is proposed here. Flow field simulations of the entire blade ECM process are carried out. The results show that in comparison with conventional flow field modes, electrolyte distribution in this new flow field mode is more uniform and the change in velocity is smaller along the flow path. In addition, the size and pressure of the liquid inlets at the leading and trailing edges were optimized, with optimal height and pressure values of 3 mm and 0.9 MPa determined, respectively. The results of experimental investigations proved that the new flow mode proposed here was reasonable, and the surface roughness and contour accuracy of the leading and trailing edges were significantly enhanced.
Similar content being viewed by others
Data availability
The manuscript has no associated data or the data will not be deposited.
References
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):081602-1-7
Bußmann M, Kraus J, Bayer E (2005) An integrated cost-effective approach to blisk manufacturing. Proceedings of 17th symposium on air breathing engines 2005
Lamphere MS, Graham JS, Robertson RS (2007) Tandem blisk electrochemical machining. Unite State Patent: US7204926B2
Klocke F, Klink A, Veselovac D, Aspinwall DK, Soo SL, Schmidt M, Schilp J, Levy G, Kruth JP (2014) Turbomachinery component manufacture by application of electrochemical, electrophysical and photonic processes. CIRP Ann 63(2):703–726
Rajurkar KP, Sundaram MM, Malshe AP (2013) Review of electrochemical and electrodischarge machining. Procedia CIRP 6(1):13–26
Zhu D, Xu ZY, Xu Q, Liu J (2010) Investigation on the flow field of W-shape electrolyte flow mode in electrochemical machining. J Appl Electrochem 40(3):525–532
Wang MH, Liu WS, Peng W (2014) Multiphysics research in electrochemical machining of internal spiral hole. Int J Adv Manuf Technol 74:749–756
Qu NS, Hu Y, Zhu D, Xu ZY (2014) Electrochemical machining of blisk channels with progressive pressure electrolyte flow. Mater Manuf Processes 29:572–578
Tang L, Gan WM (2014) Utilization of flow field simulations for cathode design in electrochemical machining of aerospace engine blisk channels. Int J Adv Manuf Technol 72(9-12):1759–1766
Zhu D, Zhang JC, Zhang KL, Liu J, Chen Z, Qu NS (2015) Electrochemical machining on blisk cascade passage with dynamic additional electrolyte flow. Int J Adv Manuf Technol 80:637–645
Gu ZZ, Zhu D, Xue TY, Liu A, Zhu D (2017) Investigation on flow field in electrochemical trepanning of aero engine diffuser. Int J Adv Manuf Technol 89(1):877–888
Li JZ, Wang DY, Zhu D, He B (2020) Analysis of the flow field in counter-rotating electrochemical machining. Journal of Materials Processing Technology 275: 116323-1-7
Xu JW, Zhu D, Lin JH, Hu XY (2020) Flow field design and experimental investigation of electrochemical trepanning of diffuser with a special structure. Int J Adv Manuf Technol 107:1551–1558
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. Procedia CIRP 8:265–270
Zhu D, Zhang, RH, Liu, C Flow field improvement by optimizing turning profile at electrolyte inlet in electrochemical machining. International Journal of Precision Engineering and Manufacturing 18(1): 15-22
McGeough JA (1974) Principles of electrochemical machining. Chapman & Hall, London
Xu ZY, Sun LY, Hu Y, Zhang JC (2014) Flow field design and experimental investigation of electrochemical machining on blisk cascade passage. Int J Adv Manuf Technol 71(1–4):459–469
Zhu D, Yu LG, Zhang RH (2018) Design of the cross-structure cathodes in electrochemical machining of aero-engine blades. Machining Science and Technology 22(5):851–864
Funding
This study was co-supported by the National Natural Science Foundation of China (No. 91860135), National Natural Science Foundation of China for Creative Research Groups (Grant No. 51921003), and the Postgraduate Research and Practice Innovation Program of Jiangsu Province (KYCX19_0164).
Author information
Authors and Affiliations
Contributions
Conceptualization:·Dong Zhu; data curation: Jianwei Guo, and Yujun Yang; formal analysis: Jianwei Guo and Yujun Yang; funding acquisition: Dong Zhu and Jianwei Guo; methodology: Dong Zhu and Jianwei Guo; project administration: Dong Zhu and Jianwei Guo; resources: Yujun Yang; simulation: Jianwei Guo and Yujun Yang; supervision: Dong Zhu and Jianwei Guo; experimental: Jianwei Guo and Yujun Yang; writing—original draft preparation: Jianwei Guo; writing—review and editing: Dong Zhu and Jianwei Guo
Corresponding author
Ethics declarations
Ethical approval
This paper is new. Neither the entire paper nor any part of its content has been published or has been accepted elsewhere. It is not being submitted to any other journal as well.
Consent to participate
Not applicable.
Consent for publication
Not applicable.
Conflict of interest
The authors declare no competing interests.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Guo, J., Zhu, D. & Yang, Y. Electrochemical machining with independent electrolyte supply at blade leading/trailing edge. Int J Adv Manuf Technol 114, 1119–1129 (2021). https://doi.org/10.1007/s00170-021-06917-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-021-06917-7