双叶片套型电解加工流场设计及优化

具有大小双叶片的扩压器能够改善压气机的性能，在航空发动机中得到广泛应用。此类构件多采用高温合金等难切削材料制造，传统铣削加工存在刀具损耗等问题。电解加工技术具有无机械切削力、工具阴极无损耗等特点。提出一种双叶片套型电解加工的方法，基于法向流程等距的原则设计了叶间出液通道，建立了出液通道宽度递增的流道模型，开展了流场仿真研究，当出液通道的宽度为0.9 mm时，加工区域内电解液的流速分布最均匀。选择GH4169材料进行了双叶片套型电解加工的对比试验，试验结果表明，采用叶间出液的电解液流动方式，加工稳定性得到提高，阴极进给速度由0.6 mm/min提高至1.0 mm/min，材料去除速率达到1 396.5 mm³/min，叶片锥度降低至1：14.29以下，轮毂表面形貌得到改善。

Design and Optimization of Flow Field in Electrochemical Trepanning for Double Blades

Diffuser with double blades (main blade and splitter blade) can further optimize the performance of compressor and is widely used in air engines. For these components made by difficult-cutting materials, traditional milling is easy to cause the loss of tools. Electrochemical machining technology (ECM) has the characteristics of no mechanical cutting force and wide machining range. A method of electrochemical trepanning for double blades is proposed. The liquid outlet channel (LOC) between blades is design based on the equal-distance of flow path. The 3D flow channel models with increasing width of LOC are established and CFD simulations are carried out. When the width is 0.9 mm, the electrolyte in the machining area has the most uniform flow rate. The results of comparative experiments with GH4169 material showed that the cathode feed rate is increased from 0.5 mm/min to 1 mm/min, and the material removal rate reached 1 396.5 mm³/min. The surface morphology of the hub is improved and the blade taper was reduced to less than 1:14.29.