大扭曲度整体涡轮叶片展成电解加工成形规律及试验研究

根据大扭曲度整体涡轮结构特点与加工难点，提出用展成电解方式实现其叶片加工；分析、研究大扭曲度整体涡轮展成电解加工叶片型面成形规律；根据其成形特点，进行多轴联动数控编程的优化；合理设计阴极及流场，对叶背二次腐蚀、出口短路及叶背余量去除等关键工艺问题进行分析讨论并提出有效解决措施；进行整体涡轮叶片展成电解加工试验，可稳定达到型面精度加工要求，为大扭曲度整体涡轮展成电解加工的应用创造了条件。

Study on the Shaping Law and Test of Electrochemical Contour Evolution Machining for Integral Turbine with Big-twisted Blades

Based on the structural features and machining difficulties about the integral turbine with big- twisted blades, an electrochemical contour evolution machining was proposed to machine the big-twisted blades. The shaping law was analyzed and studied and the twisted blades dispersed data were processed. The multi-axis cooperative numerical control programs were programmed and optimized by the shaping law. The cathode and the flowing way were designed reasonably. Key processing issues, such as the short circuit, the blade back extra corrosion in gas exit and the extra rest in gas entrance were discussed, and corresponding effective means were given. Machining tests were carried out and the integral turbines meeting the precision requirements are produced. The study is helpful for manufacturing integral turbine with big-twisted blades.