To ensure the dimensional accuracy of the final blade profile,it is necessary for precision Electrochemical Machining(ECM)of blade profile to come into an equilibrium state.However,after Electrochemical Trepanning(ECT...To ensure the dimensional accuracy of the final blade profile,it is necessary for precision Electrochemical Machining(ECM)of blade profile to come into an equilibrium state.However,after Electrochemical Trepanning(ECTr),the cascade channel of the blisk is narrow,and the blank allowance distribution is uneven,making it difficult for the precision ECM to become balanced.In blisk production,the two-step method cannot make precision ECM enter equilibrium for some blisk types.A three-step processing method is proposed to overcome this problem.The threestep method adds Electrochemical Homogenizing Machining(ECHM)between the ECTr and precision ECM steps so that the blank allowance can be homogenized quickly without unduly affecting the minimum allowance.Comparative machining experiments of the two-and three-step methods were performed to verify the improvement to blade machining accuracy.The processing results show that the contour parameters of the blade after the three-step method implementation are much better.The allowance difference of the concave(convex)side decreased by 70.5%(65%).In addition,the current in the three-step method is stable at 110 A at the end of precision ECM,verifying successfully entering the equilibrium state.展开更多
In electrochemical machining(ECM),the electrolyte flow field has a significant effect on machining stability,efficiency,and surface quality.In multitool ECM of blisk channels,the traditional open outflow mode(OOM)is p...In electrochemical machining(ECM),the electrolyte flow field has a significant effect on machining stability,efficiency,and surface quality.In multitool ECM of blisk channels,the traditional open outflow mode(OOM)is prone to flow randomness,the flow direction is not easy to control,and electrolytes interfere with each other,which causes problems with the normal conduct of machining.To improve the flow field distribution of multitool ECM,this paper proposes a constrained composite outflow mode(COM).The machining area is divided into separate isolated partitions by specific fixtures,which also provide back-pressure to the machining area.The electrolyte is injected into the machining gap and then flows out through the top and side outlets of the fixture.The flow field distribution during the process is simulated and analyzed using computational fluid dynamics.The simulation results show that the optimized flow mode improves the accessibility of the electrolyte and the uniformity of the flow distribution.ECM experiments are carried out using a specific fixture.With COM,the maximum feed rate of the cathode reaches 1.0 mm/min,and a channel with surface roughness Ra=1.54μm is machined.The suitability and effectiveness of the flow field simulation optimization are thus verified.On this basis,synchronous ECM of 15 channels is successfully realized,and the machining efficiency is found to be improved exponentially.展开更多
The blisk is a core component of an aero-engine,and electrochemical machining(ECM)is the primary method for its manufacture.Among several ECM methods for blisks,multi-tool synchronous machining is the most efficient a...The blisk is a core component of an aero-engine,and electrochemical machining(ECM)is the primary method for its manufacture.Among several ECM methods for blisks,multi-tool synchronous machining is the most efficient and advantageous for machining channels.The allowance distribution of the blank after blisk channel machining directly influences the blade profile accuracy.This paper proposes a trajectory control strategy to homogenize the allowance distribution of the blisk channel in multi-tool ECM.The strategy includes the design of the three-dimensional space motion of the tool and blisk,as well as the regulated feed speed.The structural characteristics of the blisk channel and the principle of ECM allow for designing and optimizing the multidimensional trajectory.The electric field simulations elucidate the influence law of the three-axis feed speed on the side gap.An algorithm is adopted to iteratively optimize the speeds for different positions to realize multi-dimensional motion control and allowance homogenization.The proposed trajectory control strategy is applied to ECM experiments for the blisk channel.Compared with the constant feed speed mode,the regulated speed strategy reduces the maximum allowance difference between the convex(CV)profiles by 36.18%and that between the concave(CC)profiles by 37.73%.Subsequently,the one-time ECM of eight blisk channels was successfully realized.The average time for a single channel was 12.5 min,significantly improving the machining efficiency.In conclusion,the proposed method is effective and can be extended for synchronously machining various blisk types with twisted channels.展开更多
Rotational feeding combined with shift feeding electrochemical trepanning(RF-SF ECTr)is an effective method for machining aeroengine blisks.However,given the variable relative motion of the electrodes and the complex ...Rotational feeding combined with shift feeding electrochemical trepanning(RF-SF ECTr)is an effective method for machining aeroengine blisks.However,given the variable relative motion of the electrodes and the complex flow channels around the bending and twisting blades,the accessibility and uniformity of the flow field are poor in blisk RF-SF ECTr using the traditional electrolyte supply(TES)mode,resulting in poor machining stability and low machining efficiency.To improve the distribution of the flow field,a new multi-channel electrolyte supply(MCES)mode is proposed for blisk RF-SF ECTr,in which the position and volume of the electrolyte supply are controlled effectively by setting multiple inlet channels in the liquid inlet area.A flow-field simulation comparison between TES and MCES shows that better accessibility and uniformity of the flow-field distribution are achieved under MCES.To clarify further the flow-field distribution characteristics under RF-SF ECTr,a series of flow-field simulations was conducted at different machining depths.Based on the obtained dynamic change law for the flow field,to enhance further its uniformity and accessibility,a global coverage strategy for the electrolyte supply and a flow-field structure optimization method for MCES are proposed,which involve optimizing the number,diameter,and location of the inlet channels.After many simulations,the optimal MCES structure was achieved whereby the electrolyte covers all positions effectively in the processing area.To verify the proposed method as effective and correct,a series of RF-SF ECTr experiments was carried out.Under the optimized MCES mode,the feeding rate was increased from 0.8 mm/min with the TES mode to 2.0 mm/min,and the processing stability and efficiency were improved significantly.The methods presented here offer an effective guide for flow-field optimization when machining other components with complex spatial structures.展开更多
For rough machining of a complex narrow cavity,e.g.,a complex blisk channel on an aero-engine,the typically used cutting tools are the slender cylindrical cutter and conical cutter.Nevertheless,as neither of the two i...For rough machining of a complex narrow cavity,e.g.,a complex blisk channel on an aero-engine,the typically used cutting tools are the slender cylindrical cutter and conical cutter.Nevertheless,as neither of the two is particularly suited for rough machining,wherein the main purpose is to remove a large volume as quickly as possible,the machining efficiency is low,especially when the part materials are of hard-to-cut types(e.g.,Titanium-alloy)for which it often takes days to rough machine a blisk.Fortunately,disc machining provides a new and efficient roughing solution,since a disc cutter with a large radius enables a much larger cutting speed and thus a larger material removal rate.However,due to the large radius of the disc cutter,its potential collision with narrow and twisted channels becomes a serious concern.In this paper,we propose a novel twophase approach for efficiently machining a complex narrow cavity workpiece using a disc-shaped cutter,i.e.,3+2-axis disc-slotting of the channel by multiple layers(rough machining)+five-axis disc-milling of the freeform channel side surfaces(semi-finish machining).Both simulation and physical cutting experiments are conducted to assess the effectiveness and advantages of the proposed method.The experimental results show that,with respect to a same cusp-height threshold on the channel side surfaces,the total machining time of the tested part by the proposed method is about only 36%of that by the conventional approach of plunging-milling(for roughing)plus milling by a slender cylindrical cutter(for semi-finishing).展开更多
Electrochemical trepanning(ECTr)is an effective electrochemical machining(ECM)technique that can be used to manufacture the integral components of aero-engine compressors.This study focused on the dynamic evolution of...Electrochemical trepanning(ECTr)is an effective electrochemical machining(ECM)technique that can be used to manufacture the integral components of aero-engine compressors.This study focused on the dynamic evolution of ECTr for production of inner blisks(bladed disks)with a special chamfer structure at blade tip.Due to the existence of chamfer,the ECTr process of inner blades is in a non-equilibrium state during the early stages,and the physical field changes in the machining gap are complex,making it difficult to predict the forming process.In this paper,a dynamic evolution model(DEM)of inner blade ECTr with a special chamfer at blade tip structure is proposed,and an ECTr multi-physical fields simulation study was carried out.The evolution of the chamfer at blade tip was analyzed and data related to chamfer were predicted based on the dependence of anode boundary properties with machining time and feed rate.In addition,the dis-tributions of current density,electrolyte flow rate,bubble volume fraction,temperature rise,and electrolyte conductivity in the machining area at different times were obtained by combining them with the multi-physical fields simulation results.Subsequently,a series of ECTr experiments were conducted,in which,as the feed rate increased,the surface quality and machining accuracy of the inner blades were improved.Compared with the simulation results,the error in machining accu-racy of the chamfer profile is controlled within±2%,and the machining accuracy of the blade full profile was controlled within±0.2 mm,indicating that the model proposed in this study was effec-tive in predicting the evolution of inner blades ECTr with chamfer structures at blade tip.展开更多
To obtain final parts with the desired dimensional accuracy and repeatability via electrochemical machining(ECM), the machining process must enter an ECM balanced state. However,for the ECM processing of blisk, a key ...To obtain final parts with the desired dimensional accuracy and repeatability via electrochemical machining(ECM), the machining process must enter an ECM balanced state. However,for the ECM processing of blisk, a key component of aerospace engines, the surface of the blade blank often has an uneven allowance distribution due to the narrow passage of the cascade. It is difficult to remedy this issue in subsequent processing steps, which is necessary to ensure the dimensional accuracy and repeatability of the final blade profile. To solve this problem, electrolytic machining must be preceded by electrolytic shaping, which requires cathode tools with large leveling ratios to quickly homogenize the blank surface of the blade. In this study, to obtain a cathode tool with an extremely high leveling ratio, a design method based on the variation in the electrode gap in the non-equilibrium electrolytic state is proposed, and a dissolution model based on the nonequilibrium state is established. In this design method, the allowance on the blank to be machined is first divided into many discrete allowances with the normal direction. The initial machining clearance, feed rate, and total machining time are then calculated using classical ECM equilibrium state theory based on the maximum allowance. Meanwhile, the point coordinates of the cathode tool at maximum allowance can be determined. The non-equilibrium model can then be used to calculate the relative coordinate positions corresponding to the remaining discrete allowances. Finally, the entire cathode tool profile is designed. Simulations, fundamental experiments, and blisk unit workpiece experiments were carried out to validate the design approach. In the simulated processing of the plane workpiece, the leveling ratio of the cathode tool designed by the proposed method(0.77)was 83% higher than that of the cathode tool designed using the traditional method. The simulation results were confirmed by processing experiments. In the machining of blisk unit workpieces with complex curved surfaces, the leveling ratios of the convex and concave parts of the blade machined using the proposed cathode tool respectively reached 0.75 and 0.54, which are 75% and 38% higher than those obtained using the traditional method. This new cathode design method and machining technology can significantly improve the surface allowance distribution of blank before electrolytic finishing. It is helpful for finishing machine to enter electrolytic equilibrium state. Finally, the final blade profile accuracy can be guaranteed and repeated errors can be reduced.展开更多
The integral impeller and blisk of an aero-engine are high performance parts with complex structure and made of difficult-to-cut materials. The blade surfaces of the integral impeller and blisk are functional surfaces...The integral impeller and blisk of an aero-engine are high performance parts with complex structure and made of difficult-to-cut materials. The blade surfaces of the integral impeller and blisk are functional surfaces for power transmission, and their surface integrity has signif- icant effects on the aerodynamic efficiency and service life of an aero-engine. Thus, it is indispensable to finish and strengthen the blades before use. This paper presents a comprehensive literature review of studies on finishing and strengthening technologies for the impeller and blisk of aero-engines. The review includes independent and inte- grated finishing and strengthening technologies and dis- cusses advanced rotational abrasive flow machining with back-pressure used for finishing the integral impeller and blisk. A brief assessment of future research problems and directions is also presented.展开更多
Ti60 （Ti-5.6A1-4.8Sn2Zr-1Mo-0.35Si-0.7Nd） is a high-temperature titanium alloy that is now used for important components of aircraft engines. Electrochemical machining （ECM） is a promising technique that has sever...Ti60 （Ti-5.6A1-4.8Sn2Zr-1Mo-0.35Si-0.7Nd） is a high-temperature titanium alloy that is now used for important components of aircraft engines. Electrochemical machining （ECM） is a promising technique that has several advantages, such as a high machining rate, and can be used on a wide range of difficult-to-process materials. In this paper, orthogonal experiments are conducted to investigate ECM of Ti60, with the aim of determining the influences of some electrochemical pro- cess parameters on the surface roughness. The most important parameter is found to be the frequency of the pulsed power supply. It is found that using suitably optimized parameters for ECM can greatly decrease the surface roughness ofa workpiece. A surface roughness of approximately 0.912 μm can be obtained with the following optimal parameters： NaC1 electrolyte concentration 13wt%, voltage 20 V, pulse frequency 0.4 kHz, duty cycle 0.3, temperature 23 ℃, and anode feed rate 0.5 mm/min. Furthermore, blisk blades have been successfully processed using these optimized parameters展开更多
The Blade Integrated Disk(Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutte...The Blade Integrated Disk(Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutter in the rough machining of a blisk channel, the trochoidal milling is a promising strategy since it can keep a small immersion angle in the rough milling process while maintaining the high machining efficiency. However, while toolpaths are being planned for the trochoidal milling process, the conventional methods are mainly for the planar machining area with fixed tool orientations, which cannot be used for complex channels where the multi-axis machining should be employed. To this end, this paper presents a four-axis trochoidal toolpath planning method with a ball-end cutter, and thus the blisk channel can be machined efficiently.For this to happen, the trochoidal paths are planned in the parametric domain and then mapped into the physical domain, with tool orientations controlled by the quaternion interpolation method to have smooth tool movement along the toolpaths. Both geometric simulation and physical milling experiments of the proposed method have convincingly demonstrated the validation of the proposed method.展开更多
To reasonably implement the reliability analysis and describe the significance of influencing parameters for the multi-failure modes of turbine blisk, advanced multiple response surface method (AMRSM) was proposed for...To reasonably implement the reliability analysis and describe the significance of influencing parameters for the multi-failure modes of turbine blisk, advanced multiple response surface method (AMRSM) was proposed for multi-failure mode sensitivity analysis for reliability. The mathematical model of AMRSM was established and the basic principle of multi-failure mode sensitivity analysis for reliability with AMRSM was given. The important parameters of turbine blisk failures are obtained by the multi-failure mode sensitivity analysis of turbine blisk. Through the reliability sensitivity analyses of multiple failure modes (deformation, stress and strain) with the proposed method considering fluid-thermal-solid interaction, it is shown that the comprehensive reliability of turbine blisk is 0.9931 when the allowable deformation, stress and strain are 3.7 x 10(-3) m, 1.0023 x 10(9) Pa and 1.05 x 10(-2) m/m, respectively; the main impact factors of turbine blisk failure are gas velocity, gas temperature and rotational speed. As demonstrated in the comparison of methods (Monte Carlo (MC) method, traditional response surface method (RSM), multiple response surface method (MRSM) and AMRSM), the proposed AMRSM improves computational efficiency with acceptable computational accuracy. The efforts of this study provide the AMRSM with high precision and efficiency for multi-failure mode reliability analysis, and offer a useful insight for the reliability optimization design of multi-failure mode structure. (C) 2016 Chinese Society of Aeronautics and Astronautics. Production and hosting by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license.展开更多
The work aims to provide a further investigation of the dynamic characteristics of an integral bladed disk（also called ‘blisk＇） with a Parallel Piezoelectric Network（PPN）. The PPN is constructed by parallelly in...The work aims to provide a further investigation of the dynamic characteristics of an integral bladed disk（also called ‘blisk＇） with a Parallel Piezoelectric Network（PPN）. The PPN is constructed by parallelly interconnecting the piezoelectric patches distributed in the blisk. Two kinds of PPN are considered, namely mono-periodic PPN and bi-periodic PPN. The former has a piezoelectric patch in each sector, and the later has one patch every few sectors. The vibration suppression performance of both kinds of PPN has been studied through modal analysis, forced response analysis, and statistical analysis. The research results turn out that the PPN will only affect mechanical frequencies near the electrical frequency clusters slightly, and the bi-periodic PPN will make the nodal diameter spectrum of the modes more complex, but the amplitude corresponding to the new nodal diameter component is much smaller than that of the nodal diameter component corresponding to the mono-periodic system. The mechanical coupling between the blades and the disk plays an important role in the damping effect of the PPN, and it should be paid attention to in applications. The mono-periodic PPN can effectively suppress the amplitude magnification of the forced response induced by the mistuning of the blisk; meanwhile, it can mitigate the vibration localization of the mistuned electromechanical system. If piezoelectric patches are set only in part of the sectors, the bi-periodic PPN still has a vibration suppression ability, but the effect is related to the number and spatial distribution of the piezoelectric patches.展开更多
As a key assembly in the 5-axis CNC machine tools, positioning precision of the A-axis directly affects the machining accuracy and surface quality of the parts. First of all, mechanical structure and control system of...As a key assembly in the 5-axis CNC machine tools, positioning precision of the A-axis directly affects the machining accuracy and surface quality of the parts. First of all, mechanical structure and control system of the A-axis are designed. Then, considering the influence of nonlin- ear friction, backlash, unmodeled dynamics, uncertain cutting force and other external disturbance on the control precision of the A-axis, an adaptive sliding mode control （ASMC） based on extended state observer （ESO） is proposed. ESO is employed to estimate the state variables of the unknown system and an adaptive law is adopted to compensate for the input dead-zone caused by friction, backlash and other nonlinear characteristics. Finally, stability of the closed-loop system is guaran- teed by the Lyapunov theory. Positioning experiments illustrate the perfect estimation of ESO and the stronger anti-interference and robustness of ASMC, which can improve the control precision of the A-axis by about 40 times. Processing experiments show that the ASMC can reduce the waviness, averaKe error and roughness of the nrocessed surface by 35.63%, 31.31% and 30.35%, respectively.展开更多
The large and complex structures are divided into hundreds of thousands or millions degrees of freedom（DOF） when they are calculated which will spend a lot of time and the efficiency will be extremely low. The class...The large and complex structures are divided into hundreds of thousands or millions degrees of freedom（DOF） when they are calculated which will spend a lot of time and the efficiency will be extremely low. The classical component modal synthesis method （CMSM） are used extensively, but for many structures in the engineering of high-rise buildings, aerospace systemic engineerings, marine oil platforms etc, a large amount of calculation is still needed. An improved hybrid interface substructural component modal synthesis method（HISCMSM） is proposed. The parametric model of the mistuned blisk is built by the improved HISCMSM. The double coordinating conditions of the displacement and the force are introduced to ensure the computational accuracy. Compared with the overall structure finite element model method（FEMM）, the computational time is shortened by23.86%–31.56%and the modal deviation is 0.002%–0.157% which meets the requirement of the computational accuracy. It is faster 4.46%–10.57% than the classical HISCMSM. So the improved HISCMSM is better than the classical HISCMSM and the overall structure FEMM. Meanwhile, the frequency and the modal shape are researched, considering the factors including rotational speed, gas temperature and geometry size. The strong localization phenomenon of the modal shape’s the maximum displacement and the maximum stress is observed in the second frequency band and it is the most sensitive in the frequency veering. But the localization phenomenon is relatively weak in 1st and the 3d frequency band. The localization of the modal shape is more serious under the condition of the geometric dimensioning mistuned. An improved HISCMSM is proposed, the computational efficiency of the mistuned blisk can be increased observably by this method.展开更多
In this paper, a special-purpose CAD/CAM software package, BliskCad/Cam, based on a commercial CAD/CAM software Unigraphics is developed to reduce difficulties in CNC-EDM of the shrouded turbine blisks. The software p...In this paper, a special-purpose CAD/CAM software package, BliskCad/Cam, based on a commercial CAD/CAM software Unigraphics is developed to reduce difficulties in CNC-EDM of the shrouded turbine blisks. The software package consists of five modules such as electrode design, path searching, and machining simulation module. Functions of BliskCad/Cam include parametrical reconstruction of 3-D model of the blisk, intelligent design of complex shaped electrode, automatic generation of NC codes, search of interference-free tool path for multi-axis NC-EDM and machining simulation, etc. Experimental verification is conducted by using BliskCad/Cam and the results show that it satisfies the requirements, and can realize precision machining and reduce accessorial time remarkably.展开更多
Electrochemical machining(ECM)is an economical and effective method for blisk manufacturing and includes two steps:channel machining and profile machining.The allowance distribution after the channel machining will di...Electrochemical machining(ECM)is an economical and effective method for blisk manufacturing and includes two steps:channel machining and profile machining.The allowance distribution after the channel machining will directly affect the profile machining.Therefore,to improve the uniformity of allowance distribution in the machining of channels,a method that incorporates a variable feed rate mode is developed.During the machining process,the feed rates are dynamically changed according to the needs of the side gap at the different feed depths.As a result,the side gaps at the different feed depths vary,contributing to a decrease in the allowance difference.In this study,the dissolution processes of a blisk channel are simulated using different feed rates,and prediction profiles are obtained.Based on the prediction profiles,the relationship among the feed rate,feed depth,and side gap is established.Then,the feed rates at different feed depths are adjusted according to the relationship.In addition,contrast experiments are conducted.Compared with blisk channel ECM using a constant feed rate of 1 mm/min,using the variable feed rate decreases the allowance differences in the convex and concave parts by 62.2%and 67.4%,respectively.This indicates that using the variable feed rate in the ECM process for a blisk channel is feasible and efficient.展开更多
Electrochemical machining(ECM)has emerged as an important option for manufacturing the blisk.The inter-electrode gap(IEG)distribution is an essential parameter for the blisk precise shap-ing process in ECM,as it affec...Electrochemical machining(ECM)has emerged as an important option for manufacturing the blisk.The inter-electrode gap(IEG)distribution is an essential parameter for the blisk precise shap-ing process in ECM,as it affects the process stability,profile accuracy and surface quality.Larger IEG leads to a poor localization effect and has an adverse influence on the machining accuracy and surface quality of blisk.To achieve micro-IEG(<50 lm)blisk finishing machining,this work puts forward a novel variable-parameters blisk ECM strategy based on the synchronous coupling mode of micro-vibration amplitude and small pulse duration.The modelling and simulation of the blisk micro-IEG machining have been carried out.Exploratory experiments of variable-parameters blisk ECM were car-ried out.The results illustrated that the IEG width reduced with the progress of variable parameter pro-cess.The IEG width of the blade’s concave part and convex part could be successfully controlled to within 30 lm and 21 lm,respectively.The profile deviation for the blade’s concave surface and convex surface are 49 lm and 35 lm,while the surface roughness reaches R_(a)=0.149 lm and R_(a)=0.196 lm,respectively.The profile accuracy of the blisk leading/trailing edges was limited to within 91 lm.Com-pared with the currently-established process,the profile accuracy of the blade’s concave and convex profiles was improved by 50.5%and 53.3%,respectively.The surface quality was improved by 53.2%and 50.9%,respectively.Additionally,the machined surface was covered with small corrosion pits and weak attacks of the grain boundary due to selective dissolution.Some electrolytic products were dispersed on the machined surface,and their components were mainly composed of the carbide and oxide products of Ti and Nb elements.The results indicate that the variable-parameters strategy is effective for achieving a tiny IEG in blisk ECM,which can be used in engineering practice.展开更多
A turbine blisk, which combines blades and a disk together, is one of the most important components of an aero engine. In the process of blisk electrochemical machining （ECM）, the sheet cathode, which is usually use...A turbine blisk, which combines blades and a disk together, is one of the most important components of an aero engine. In the process of blisk electrochemical machining （ECM）, the sheet cathode, which is usually used as a tool electrode, has a complicated structure. In addition to that, the channel between the adjacent blades is narrow and twisted, so interference is apt to happen when the sheet cathode feeds into the channel. Therefore, it is important to choose suitable trajectory control strategy. In this paper, a new trajectory control strategy of the sheet cathode is presented and corresponding simulation analysis is conducted on the basis of an actual blisk model. The simulation results demonstrate that the sheet cathode can feed into the channel by a spatial line trajectory without interference. Moreover, the verification experiments are carried out according to the simulation. The experimental results show that the cathode can move into the channel without interference. It is verified that the new trajectory control strategy is correct and can be used in the blisk ECM process successfully.展开更多
Blisks with the integral structure are key parts used in new jet engines to promote the performance of aircrafts,which also increases the complexity of tool orientation planning in the five-axis machining.It is an ess...Blisks with the integral structure are key parts used in new jet engines to promote the performance of aircrafts,which also increases the complexity of tool orientation planning in the five-axis machining.It is an essential task to find the collision-free tool orientation when the tool holder is pushed deep into the channel of blisk to increase rigidity and reduce vibration.Since the radius of the holder varies with the height,the line-visibility is no longer applicable when constructing collision-free regions of tool orientation.In this paper,a method of constructing collisionfree regions without interference checking is proposed.The work of finding collision-free regions resorts to solving the local contact curves on the checking surfaces of blisk.And it further transforms into searching the locally tangent points(named critical points)between the holder and surface.Then a tracking-based algorithm is proposed to search the sample critical points on these local contact curves.And the corresponding critical vectors are also calculated synchronously.Besides,the safety allowance,discrete precision and acceptable deviation are introduced in the algorithm to ensure accuracy by controlling the angle between two adjacent critical vectors properly.After that,the searched critical vectors are mapped orderly to two-dimensional space and the collisionfree regions are constructed.This method is finally verified and compared with a referenced method.The results show that the proposed method can efficiently construct collision-free regions for holder under the given accuracy.展开更多
Flow field is a crucial factor to influence the stability and surface quality in the electrochemical machining(ECM)of blisks.A four-way flow mode was proposed to eliminate mixing regions of electrolyte at the leading ...Flow field is a crucial factor to influence the stability and surface quality in the electrochemical machining(ECM)of blisks.A four-way flow mode was proposed to eliminate mixing regions of electrolyte at the leading and tailing edges.Two flow field models were described separately in this report:a W-shaped flow mode and a four-way flow mode.The flow field was analyzed through a finite element method.The results showed that,in comparison with the W-shaped flow mode,the distribution of electrolyte flow was more uniformed and the mixed region in the flow channel was improved.The pressure of the leading and tailing edges inlets was optimized,and optimal pressure of 0.6 MPa was determined.In addition,verification experiments were performed,and the results showed that the stability,efficiency,and quality of the profiles of the blisk blade manufactured by ECM were enhanced in the new flow mode.展开更多
基金supported by the National Natural Science Foundation of China(No.52075253)the Innovation Research Team of the National Natural Science Foundation of China(No.51921003)。
文摘To ensure the dimensional accuracy of the final blade profile,it is necessary for precision Electrochemical Machining(ECM)of blade profile to come into an equilibrium state.However,after Electrochemical Trepanning(ECTr),the cascade channel of the blisk is narrow,and the blank allowance distribution is uneven,making it difficult for the precision ECM to become balanced.In blisk production,the two-step method cannot make precision ECM enter equilibrium for some blisk types.A three-step processing method is proposed to overcome this problem.The threestep method adds Electrochemical Homogenizing Machining(ECHM)between the ECTr and precision ECM steps so that the blank allowance can be homogenized quickly without unduly affecting the minimum allowance.Comparative machining experiments of the two-and three-step methods were performed to verify the improvement to blade machining accuracy.The processing results show that the contour parameters of the blade after the three-step method implementation are much better.The allowance difference of the concave(convex)side decreased by 70.5%(65%).In addition,the current in the three-step method is stable at 110 A at the end of precision ECM,verifying successfully entering the equilibrium state.
基金Supported by National Natural Science Foundation of China(Grant Nos.52075253,51921003)the Industrial Technology Development Program(Grant No.JCKY2021605B026)。
文摘In electrochemical machining(ECM),the electrolyte flow field has a significant effect on machining stability,efficiency,and surface quality.In multitool ECM of blisk channels,the traditional open outflow mode(OOM)is prone to flow randomness,the flow direction is not easy to control,and electrolytes interfere with each other,which causes problems with the normal conduct of machining.To improve the flow field distribution of multitool ECM,this paper proposes a constrained composite outflow mode(COM).The machining area is divided into separate isolated partitions by specific fixtures,which also provide back-pressure to the machining area.The electrolyte is injected into the machining gap and then flows out through the top and side outlets of the fixture.The flow field distribution during the process is simulated and analyzed using computational fluid dynamics.The simulation results show that the optimized flow mode improves the accessibility of the electrolyte and the uniformity of the flow distribution.ECM experiments are carried out using a specific fixture.With COM,the maximum feed rate of the cathode reaches 1.0 mm/min,and a channel with surface roughness Ra=1.54μm is machined.The suitability and effectiveness of the flow field simulation optimization are thus verified.On this basis,synchronous ECM of 15 channels is successfully realized,and the machining efficiency is found to be improved exponentially.
基金co-supported by the National Natural Science Foundation of China(No.52075253)the National Natural Science Foundation of China for Creative Research Groups(No.51921003)the Industrial Technology Development Program(No.JCKY2021605B026)。
文摘The blisk is a core component of an aero-engine,and electrochemical machining(ECM)is the primary method for its manufacture.Among several ECM methods for blisks,multi-tool synchronous machining is the most efficient and advantageous for machining channels.The allowance distribution of the blank after blisk channel machining directly influences the blade profile accuracy.This paper proposes a trajectory control strategy to homogenize the allowance distribution of the blisk channel in multi-tool ECM.The strategy includes the design of the three-dimensional space motion of the tool and blisk,as well as the regulated feed speed.The structural characteristics of the blisk channel and the principle of ECM allow for designing and optimizing the multidimensional trajectory.The electric field simulations elucidate the influence law of the three-axis feed speed on the side gap.An algorithm is adopted to iteratively optimize the speeds for different positions to realize multi-dimensional motion control and allowance homogenization.The proposed trajectory control strategy is applied to ECM experiments for the blisk channel.Compared with the constant feed speed mode,the regulated speed strategy reduces the maximum allowance difference between the convex(CV)profiles by 36.18%and that between the concave(CC)profiles by 37.73%.Subsequently,the one-time ECM of eight blisk channels was successfully realized.The average time for a single channel was 12.5 min,significantly improving the machining efficiency.In conclusion,the proposed method is effective and can be extended for synchronously machining various blisk types with twisted channels.
基金Supported by National Natural Science Foundation of China(Grant Nos.52275435,52075465,52375519)Open Fund Project of Jiangsu Key Laboratory of Precision and Micro-manufacturing Technology(Grant No.JSKL2324K03)Key Research and Development Program of Hunan Province of China(Grant No.2023GK2026)。
文摘Rotational feeding combined with shift feeding electrochemical trepanning(RF-SF ECTr)is an effective method for machining aeroengine blisks.However,given the variable relative motion of the electrodes and the complex flow channels around the bending and twisting blades,the accessibility and uniformity of the flow field are poor in blisk RF-SF ECTr using the traditional electrolyte supply(TES)mode,resulting in poor machining stability and low machining efficiency.To improve the distribution of the flow field,a new multi-channel electrolyte supply(MCES)mode is proposed for blisk RF-SF ECTr,in which the position and volume of the electrolyte supply are controlled effectively by setting multiple inlet channels in the liquid inlet area.A flow-field simulation comparison between TES and MCES shows that better accessibility and uniformity of the flow-field distribution are achieved under MCES.To clarify further the flow-field distribution characteristics under RF-SF ECTr,a series of flow-field simulations was conducted at different machining depths.Based on the obtained dynamic change law for the flow field,to enhance further its uniformity and accessibility,a global coverage strategy for the electrolyte supply and a flow-field structure optimization method for MCES are proposed,which involve optimizing the number,diameter,and location of the inlet channels.After many simulations,the optimal MCES structure was achieved whereby the electrolyte covers all positions effectively in the processing area.To verify the proposed method as effective and correct,a series of RF-SF ECTr experiments was carried out.Under the optimized MCES mode,the feeding rate was increased from 0.8 mm/min with the TES mode to 2.0 mm/min,and the processing stability and efficiency were improved significantly.The methods presented here offer an effective guide for flow-field optimization when machining other components with complex spatial structures.
基金supported in part by Foshan HKUST Projects(Project ID:FSUST20-SRI09E–FSPM02202007-1)the Project of Hetao Shenzhen-Hong Kong Science and Technology Innovation Cooperation Zone(Project ID:HZQB-KCZYB-2020083)the National Science and Technology Major Project(Grant No.J2019-VII-0001-0141)。
文摘For rough machining of a complex narrow cavity,e.g.,a complex blisk channel on an aero-engine,the typically used cutting tools are the slender cylindrical cutter and conical cutter.Nevertheless,as neither of the two is particularly suited for rough machining,wherein the main purpose is to remove a large volume as quickly as possible,the machining efficiency is low,especially when the part materials are of hard-to-cut types(e.g.,Titanium-alloy)for which it often takes days to rough machine a blisk.Fortunately,disc machining provides a new and efficient roughing solution,since a disc cutter with a large radius enables a much larger cutting speed and thus a larger material removal rate.However,due to the large radius of the disc cutter,its potential collision with narrow and twisted channels becomes a serious concern.In this paper,we propose a novel twophase approach for efficiently machining a complex narrow cavity workpiece using a disc-shaped cutter,i.e.,3+2-axis disc-slotting of the channel by multiple layers(rough machining)+five-axis disc-milling of the freeform channel side surfaces(semi-finish machining).Both simulation and physical cutting experiments are conducted to assess the effectiveness and advantages of the proposed method.The experimental results show that,with respect to a same cusp-height threshold on the channel side surfaces,the total machining time of the tested part by the proposed method is about only 36%of that by the conventional approach of plunging-milling(for roughing)plus milling by a slender cylindrical cutter(for semi-finishing).
基金the National Nature Science Foundation of China (52275435)the National Natural Science Foundation of China for Creative Research Groups (51921003)the National Science and Technology Major Project (2017-VII-0004-0097).
文摘Electrochemical trepanning(ECTr)is an effective electrochemical machining(ECM)technique that can be used to manufacture the integral components of aero-engine compressors.This study focused on the dynamic evolution of ECTr for production of inner blisks(bladed disks)with a special chamfer structure at blade tip.Due to the existence of chamfer,the ECTr process of inner blades is in a non-equilibrium state during the early stages,and the physical field changes in the machining gap are complex,making it difficult to predict the forming process.In this paper,a dynamic evolution model(DEM)of inner blade ECTr with a special chamfer at blade tip structure is proposed,and an ECTr multi-physical fields simulation study was carried out.The evolution of the chamfer at blade tip was analyzed and data related to chamfer were predicted based on the dependence of anode boundary properties with machining time and feed rate.In addition,the dis-tributions of current density,electrolyte flow rate,bubble volume fraction,temperature rise,and electrolyte conductivity in the machining area at different times were obtained by combining them with the multi-physical fields simulation results.Subsequently,a series of ECTr experiments were conducted,in which,as the feed rate increased,the surface quality and machining accuracy of the inner blades were improved.Compared with the simulation results,the error in machining accu-racy of the chamfer profile is controlled within±2%,and the machining accuracy of the blade full profile was controlled within±0.2 mm,indicating that the model proposed in this study was effec-tive in predicting the evolution of inner blades ECTr with chamfer structures at blade tip.
基金sponsored by the Industrial Technology Development Program (Grant No. JCKY2021605B026, and National Natural Science Foundation of China (Grant No. 92160301))。
文摘To obtain final parts with the desired dimensional accuracy and repeatability via electrochemical machining(ECM), the machining process must enter an ECM balanced state. However,for the ECM processing of blisk, a key component of aerospace engines, the surface of the blade blank often has an uneven allowance distribution due to the narrow passage of the cascade. It is difficult to remedy this issue in subsequent processing steps, which is necessary to ensure the dimensional accuracy and repeatability of the final blade profile. To solve this problem, electrolytic machining must be preceded by electrolytic shaping, which requires cathode tools with large leveling ratios to quickly homogenize the blank surface of the blade. In this study, to obtain a cathode tool with an extremely high leveling ratio, a design method based on the variation in the electrode gap in the non-equilibrium electrolytic state is proposed, and a dissolution model based on the nonequilibrium state is established. In this design method, the allowance on the blank to be machined is first divided into many discrete allowances with the normal direction. The initial machining clearance, feed rate, and total machining time are then calculated using classical ECM equilibrium state theory based on the maximum allowance. Meanwhile, the point coordinates of the cathode tool at maximum allowance can be determined. The non-equilibrium model can then be used to calculate the relative coordinate positions corresponding to the remaining discrete allowances. Finally, the entire cathode tool profile is designed. Simulations, fundamental experiments, and blisk unit workpiece experiments were carried out to validate the design approach. In the simulated processing of the plane workpiece, the leveling ratio of the cathode tool designed by the proposed method(0.77)was 83% higher than that of the cathode tool designed using the traditional method. The simulation results were confirmed by processing experiments. In the machining of blisk unit workpieces with complex curved surfaces, the leveling ratios of the convex and concave parts of the blade machined using the proposed cathode tool respectively reached 0.75 and 0.54, which are 75% and 38% higher than those obtained using the traditional method. This new cathode design method and machining technology can significantly improve the surface allowance distribution of blank before electrolytic finishing. It is helpful for finishing machine to enter electrolytic equilibrium state. Finally, the final blade profile accuracy can be guaranteed and repeated errors can be reduced.
基金Supported by Science Fund for Creative Research Groups of NSFC(51621064)National Natural Science Foundation of China(Grant No.51475074,11302043)the Fundamental Research Funds for the Central Universities(DUT15QY37)
文摘The integral impeller and blisk of an aero-engine are high performance parts with complex structure and made of difficult-to-cut materials. The blade surfaces of the integral impeller and blisk are functional surfaces for power transmission, and their surface integrity has signif- icant effects on the aerodynamic efficiency and service life of an aero-engine. Thus, it is indispensable to finish and strengthen the blades before use. This paper presents a comprehensive literature review of studies on finishing and strengthening technologies for the impeller and blisk of aero-engines. The review includes independent and inte- grated finishing and strengthening technologies and dis- cusses advanced rotational abrasive flow machining with back-pressure used for finishing the integral impeller and blisk. A brief assessment of future research problems and directions is also presented.
基金co-supported by the Natural Science Foundation of China(No.51205199)the Program for New Century Excellent Talents in University(NCET-12-0627)of China+2 种基金the Fundamental Research Funds for the Central Universities(NE2014104)of Chinathe Funding of Jiangsu Innovation Program for Graduate Education(No.CXLX13_141)of Chinathe Fundamental Research Funds for the Central Universities of China
文摘Ti60 （Ti-5.6A1-4.8Sn2Zr-1Mo-0.35Si-0.7Nd） is a high-temperature titanium alloy that is now used for important components of aircraft engines. Electrochemical machining （ECM） is a promising technique that has several advantages, such as a high machining rate, and can be used on a wide range of difficult-to-process materials. In this paper, orthogonal experiments are conducted to investigate ECM of Ti60, with the aim of determining the influences of some electrochemical pro- cess parameters on the surface roughness. The most important parameter is found to be the frequency of the pulsed power supply. It is found that using suitably optimized parameters for ECM can greatly decrease the surface roughness ofa workpiece. A surface roughness of approximately 0.912 μm can be obtained with the following optimal parameters： NaC1 electrolyte concentration 13wt%, voltage 20 V, pulse frequency 0.4 kHz, duty cycle 0.3, temperature 23 ℃, and anode feed rate 0.5 mm/min. Furthermore, blisk blades have been successfully processed using these optimized parameters
基金supported by the China National Science and Technology Major Project(No.2015ZX04001202)
文摘The Blade Integrated Disk(Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutter in the rough machining of a blisk channel, the trochoidal milling is a promising strategy since it can keep a small immersion angle in the rough milling process while maintaining the high machining efficiency. However, while toolpaths are being planned for the trochoidal milling process, the conventional methods are mainly for the planar machining area with fixed tool orientations, which cannot be used for complex channels where the multi-axis machining should be employed. To this end, this paper presents a four-axis trochoidal toolpath planning method with a ball-end cutter, and thus the blisk channel can be machined efficiently.For this to happen, the trochoidal paths are planned in the parametric domain and then mapped into the physical domain, with tool orientations controlled by the quaternion interpolation method to have smooth tool movement along the toolpaths. Both geometric simulation and physical milling experiments of the proposed method have convincingly demonstrated the validation of the proposed method.
基金co-supported by the National Natural Science Foundation of China (No. 51275138)the Science Foundation of Heilongjiang Provincial Department of Education (No. 12531109)+1 种基金the funding of Hong Kong Scholars Programs (Nos. XJ2015002 and G-YZ90)China’s Postdoctoral Science Funding (No. 2015M580037)
文摘To reasonably implement the reliability analysis and describe the significance of influencing parameters for the multi-failure modes of turbine blisk, advanced multiple response surface method (AMRSM) was proposed for multi-failure mode sensitivity analysis for reliability. The mathematical model of AMRSM was established and the basic principle of multi-failure mode sensitivity analysis for reliability with AMRSM was given. The important parameters of turbine blisk failures are obtained by the multi-failure mode sensitivity analysis of turbine blisk. Through the reliability sensitivity analyses of multiple failure modes (deformation, stress and strain) with the proposed method considering fluid-thermal-solid interaction, it is shown that the comprehensive reliability of turbine blisk is 0.9931 when the allowable deformation, stress and strain are 3.7 x 10(-3) m, 1.0023 x 10(9) Pa and 1.05 x 10(-2) m/m, respectively; the main impact factors of turbine blisk failure are gas velocity, gas temperature and rotational speed. As demonstrated in the comparison of methods (Monte Carlo (MC) method, traditional response surface method (RSM), multiple response surface method (MRSM) and AMRSM), the proposed AMRSM improves computational efficiency with acceptable computational accuracy. The efforts of this study provide the AMRSM with high precision and efficiency for multi-failure mode reliability analysis, and offer a useful insight for the reliability optimization design of multi-failure mode structure. (C) 2016 Chinese Society of Aeronautics and Astronautics. Production and hosting by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license.
基金support of the National Natural Science Foundation of China (No. 51675022, 11702011)China Postdoctoral Science Foundation (No. 2017M610741)
文摘The work aims to provide a further investigation of the dynamic characteristics of an integral bladed disk（also called ‘blisk＇） with a Parallel Piezoelectric Network（PPN）. The PPN is constructed by parallelly interconnecting the piezoelectric patches distributed in the blisk. Two kinds of PPN are considered, namely mono-periodic PPN and bi-periodic PPN. The former has a piezoelectric patch in each sector, and the later has one patch every few sectors. The vibration suppression performance of both kinds of PPN has been studied through modal analysis, forced response analysis, and statistical analysis. The research results turn out that the PPN will only affect mechanical frequencies near the electrical frequency clusters slightly, and the bi-periodic PPN will make the nodal diameter spectrum of the modes more complex, but the amplitude corresponding to the new nodal diameter component is much smaller than that of the nodal diameter component corresponding to the mono-periodic system. The mechanical coupling between the blades and the disk plays an important role in the damping effect of the PPN, and it should be paid attention to in applications. The mono-periodic PPN can effectively suppress the amplitude magnification of the forced response induced by the mistuning of the blisk; meanwhile, it can mitigate the vibration localization of the mistuned electromechanical system. If piezoelectric patches are set only in part of the sectors, the bi-periodic PPN still has a vibration suppression ability, but the effect is related to the number and spatial distribution of the piezoelectric patches.
基金supported by National Science and Technology Major Project of the Ministry of Science and Technology of China (No. 2013ZX04001081)
文摘As a key assembly in the 5-axis CNC machine tools, positioning precision of the A-axis directly affects the machining accuracy and surface quality of the parts. First of all, mechanical structure and control system of the A-axis are designed. Then, considering the influence of nonlin- ear friction, backlash, unmodeled dynamics, uncertain cutting force and other external disturbance on the control precision of the A-axis, an adaptive sliding mode control （ASMC） based on extended state observer （ESO） is proposed. ESO is employed to estimate the state variables of the unknown system and an adaptive law is adopted to compensate for the input dead-zone caused by friction, backlash and other nonlinear characteristics. Finally, stability of the closed-loop system is guaran- teed by the Lyapunov theory. Positioning experiments illustrate the perfect estimation of ESO and the stronger anti-interference and robustness of ASMC, which can improve the control precision of the A-axis by about 40 times. Processing experiments show that the ASMC can reduce the waviness, averaKe error and roughness of the nrocessed surface by 35.63%, 31.31% and 30.35%, respectively.
基金Supported by National Natural Science Foundation of China (Grant Nos.51375032,51335003)
文摘The large and complex structures are divided into hundreds of thousands or millions degrees of freedom（DOF） when they are calculated which will spend a lot of time and the efficiency will be extremely low. The classical component modal synthesis method （CMSM） are used extensively, but for many structures in the engineering of high-rise buildings, aerospace systemic engineerings, marine oil platforms etc, a large amount of calculation is still needed. An improved hybrid interface substructural component modal synthesis method（HISCMSM） is proposed. The parametric model of the mistuned blisk is built by the improved HISCMSM. The double coordinating conditions of the displacement and the force are introduced to ensure the computational accuracy. Compared with the overall structure finite element model method（FEMM）, the computational time is shortened by23.86%–31.56%and the modal deviation is 0.002%–0.157% which meets the requirement of the computational accuracy. It is faster 4.46%–10.57% than the classical HISCMSM. So the improved HISCMSM is better than the classical HISCMSM and the overall structure FEMM. Meanwhile, the frequency and the modal shape are researched, considering the factors including rotational speed, gas temperature and geometry size. The strong localization phenomenon of the modal shape’s the maximum displacement and the maximum stress is observed in the second frequency band and it is the most sensitive in the frequency veering. But the localization phenomenon is relatively weak in 1st and the 3d frequency band. The localization of the modal shape is more serious under the condition of the geometric dimensioning mistuned. An improved HISCMSM is proposed, the computational efficiency of the mistuned blisk can be increased observably by this method.
文摘In this paper, a special-purpose CAD/CAM software package, BliskCad/Cam, based on a commercial CAD/CAM software Unigraphics is developed to reduce difficulties in CNC-EDM of the shrouded turbine blisks. The software package consists of five modules such as electrode design, path searching, and machining simulation module. Functions of BliskCad/Cam include parametrical reconstruction of 3-D model of the blisk, intelligent design of complex shaped electrode, automatic generation of NC codes, search of interference-free tool path for multi-axis NC-EDM and machining simulation, etc. Experimental verification is conducted by using BliskCad/Cam and the results show that it satisfies the requirements, and can realize precision machining and reduce accessorial time remarkably.
基金the National Science and Technology Major Project(No.2017-VII-0004-0097)the Natural Science Foundation for Distinguished Young Scholars of Jiangsu Province(No.BK20170031)。
文摘Electrochemical machining(ECM)is an economical and effective method for blisk manufacturing and includes two steps:channel machining and profile machining.The allowance distribution after the channel machining will directly affect the profile machining.Therefore,to improve the uniformity of allowance distribution in the machining of channels,a method that incorporates a variable feed rate mode is developed.During the machining process,the feed rates are dynamically changed according to the needs of the side gap at the different feed depths.As a result,the side gaps at the different feed depths vary,contributing to a decrease in the allowance difference.In this study,the dissolution processes of a blisk channel are simulated using different feed rates,and prediction profiles are obtained.Based on the prediction profiles,the relationship among the feed rate,feed depth,and side gap is established.Then,the feed rates at different feed depths are adjusted according to the relationship.In addition,contrast experiments are conducted.Compared with blisk channel ECM using a constant feed rate of 1 mm/min,using the variable feed rate decreases the allowance differences in the convex and concave parts by 62.2%and 67.4%,respectively.This indicates that using the variable feed rate in the ECM process for a blisk channel is feasible and efficient.
基金sponsored by the National Science and Tech-nology Major Project(Grant No.2017-VII-0004-0097)National Natural Science Foundation of China for Creative Research Groups(Grant No.51921003)the Postgraduate Research&Practice Innovation Program of Jiangsu Province(Grant No.KYCX21_0191).
文摘Electrochemical machining(ECM)has emerged as an important option for manufacturing the blisk.The inter-electrode gap(IEG)distribution is an essential parameter for the blisk precise shap-ing process in ECM,as it affects the process stability,profile accuracy and surface quality.Larger IEG leads to a poor localization effect and has an adverse influence on the machining accuracy and surface quality of blisk.To achieve micro-IEG(<50 lm)blisk finishing machining,this work puts forward a novel variable-parameters blisk ECM strategy based on the synchronous coupling mode of micro-vibration amplitude and small pulse duration.The modelling and simulation of the blisk micro-IEG machining have been carried out.Exploratory experiments of variable-parameters blisk ECM were car-ried out.The results illustrated that the IEG width reduced with the progress of variable parameter pro-cess.The IEG width of the blade’s concave part and convex part could be successfully controlled to within 30 lm and 21 lm,respectively.The profile deviation for the blade’s concave surface and convex surface are 49 lm and 35 lm,while the surface roughness reaches R_(a)=0.149 lm and R_(a)=0.196 lm,respectively.The profile accuracy of the blisk leading/trailing edges was limited to within 91 lm.Com-pared with the currently-established process,the profile accuracy of the blade’s concave and convex profiles was improved by 50.5%and 53.3%,respectively.The surface quality was improved by 53.2%and 50.9%,respectively.Additionally,the machined surface was covered with small corrosion pits and weak attacks of the grain boundary due to selective dissolution.Some electrolytic products were dispersed on the machined surface,and their components were mainly composed of the carbide and oxide products of Ti and Nb elements.The results indicate that the variable-parameters strategy is effective for achieving a tiny IEG in blisk ECM,which can be used in engineering practice.
基金co-supported by the National Natural Science Foundation of China(No.51205199)the Open Project of State Key Laboratory of Mechanical System and Vibration(No.MSV201217)
文摘A turbine blisk, which combines blades and a disk together, is one of the most important components of an aero engine. In the process of blisk electrochemical machining （ECM）, the sheet cathode, which is usually used as a tool electrode, has a complicated structure. In addition to that, the channel between the adjacent blades is narrow and twisted, so interference is apt to happen when the sheet cathode feeds into the channel. Therefore, it is important to choose suitable trajectory control strategy. In this paper, a new trajectory control strategy of the sheet cathode is presented and corresponding simulation analysis is conducted on the basis of an actual blisk model. The simulation results demonstrate that the sheet cathode can feed into the channel by a spatial line trajectory without interference. Moreover, the verification experiments are carried out according to the simulation. The experimental results show that the cathode can move into the channel without interference. It is verified that the new trajectory control strategy is correct and can be used in the blisk ECM process successfully.
基金the National Natural Science Foundation of China(No.51675439)。
文摘Blisks with the integral structure are key parts used in new jet engines to promote the performance of aircrafts,which also increases the complexity of tool orientation planning in the five-axis machining.It is an essential task to find the collision-free tool orientation when the tool holder is pushed deep into the channel of blisk to increase rigidity and reduce vibration.Since the radius of the holder varies with the height,the line-visibility is no longer applicable when constructing collision-free regions of tool orientation.In this paper,a method of constructing collisionfree regions without interference checking is proposed.The work of finding collision-free regions resorts to solving the local contact curves on the checking surfaces of blisk.And it further transforms into searching the locally tangent points(named critical points)between the holder and surface.Then a tracking-based algorithm is proposed to search the sample critical points on these local contact curves.And the corresponding critical vectors are also calculated synchronously.Besides,the safety allowance,discrete precision and acceptable deviation are introduced in the algorithm to ensure accuracy by controlling the angle between two adjacent critical vectors properly.After that,the searched critical vectors are mapped orderly to two-dimensional space and the collisionfree regions are constructed.This method is finally verified and compared with a referenced method.The results show that the proposed method can efficiently construct collision-free regions for holder under the given accuracy.
基金co-supported by the National Nature Science Foundation of China(No.91860135)National Natural Science Foundation of China for Creative Research Groups(No.51921003)National Science and Technology Major Project(No.2017-VII-0004-0097)。
文摘Flow field is a crucial factor to influence the stability and surface quality in the electrochemical machining(ECM)of blisks.A four-way flow mode was proposed to eliminate mixing regions of electrolyte at the leading and tailing edges.Two flow field models were described separately in this report:a W-shaped flow mode and a four-way flow mode.The flow field was analyzed through a finite element method.The results showed that,in comparison with the W-shaped flow mode,the distribution of electrolyte flow was more uniformed and the mixed region in the flow channel was improved.The pressure of the leading and tailing edges inlets was optimized,and optimal pressure of 0.6 MPa was determined.In addition,verification experiments were performed,and the results showed that the stability,efficiency,and quality of the profiles of the blisk blade manufactured by ECM were enhanced in the new flow mode.
