The Effects of Normal Gap Distribution on Cathode Design of Aero-Engine Blades in Electrochemical Machining

2010 ◽  
Vol 97-101 ◽  
pp. 3583-3586 ◽  
Author(s):  
Zhi Yong Li ◽  
Hua Ji
Keyword(s):  
Design Method ◽  
Electrochemical Machining ◽  
Difficult Problem ◽  
Machining Process ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Three Dimension ◽  
Cathode Design ◽  
Aero Engine ◽  
Machining Rate

Cathode design is a difficult problem must be faced and solved in electrochemical machining (ECM). In ECM process, various parameters, such as applied voltage, current density, gap distribution, machining rate and electrolyte composition and concentration, can affect ECM machining process and therefore cathode design. Among all these machining parameters, gap distribution is the most vital. Regard some type of aero-engine compressor blade as research object, this paper concentrates on the effects of the normal gap distribution of 2-dimension and 3-dimension on cathode design based on the cathode design method of , moreover the errors between two and three dimension normal gap also can be compared and analyzed in detail. To verify the accuracy of the designed cathode, the machining experiments were conducted on an industrial scale ECM machine and the experimental results demonstrates that the cathode designed utilizing 3-dimension normal gap exhibits more machining accuracy and therefore valuable.

Machining Parameter Optimization of Aero-Engine Blade in Electrochemical Machining Based on BP Neural Network

2010 ◽  
Vol 121-122 ◽  
pp. 893-899 ◽  
Author(s):  
Zhi Yong Li ◽  
Hua Ji ◽  
Hong Li Liu
Keyword(s):  
Neural Network ◽  
Bp Neural Network ◽  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Parameter Combination ◽  
Aero Engine ◽  
Engine Blade ◽  
Blade Machining ◽  
Machining Parameter

Because the process of blade in electrochemical machining(EMC) can be effected by many factors, such as blade shapes, machining electrical field, electrolyte fluid field and anode electrochemical dissolution, different ECM machining parameters maybe result in great affections on blade machining accuracy. Regard some type of aero-engine blade as research object, five main machining parameters, applied voltage, initial machining gap, cathode feed rate, electrolyte temperature and pressure difference between electrolyte inlet and outlet, have been evaluated and optimized based on BP neural network technique. From 3125 possible machining parameter combinations, 657 optimized parameter combinations are discovered. To verify the validity of the optimized ECM parameter combination, a serial of machining experiments have been conducted on an industrial scale ECM machine, and the experiment results demonstrates that the optimized ECM parameter combination not only can satisfy the manufacturing requirements of blade fully but has excellent ECM process stability.

Experimental Investigation of a New Grid Cathode Design Method in Electrochemical Machining

2013 ◽  
Vol 135 (2) ◽  
Author(s):  
Lu Yonghua ◽  
Zhao Dongbiao ◽  
Liu Kai
Keyword(s):  
Design Method ◽  
Electrochemical Machining ◽  
Grid Cell ◽  
Machining Process ◽  
Cathode Design ◽  
Complex Shapes ◽  
Equivalent Area ◽  
Square Cells ◽  
Grid Cathode ◽  
Circular Grid

This paper focuses on the grid cathode design in electrochemical machining (ECM) in order to develop a new cathode design method for realizing a breakthrough: one cathode can produce different workpieces with different profiles. Three types of square cells, 2.5 mm × 2.5 mm, 3 mm × 3 mm, and 4 mm × 4 mm in size and three types of circular cells, with diameters of 1.5, 2.0, and 2.5 mm are utilized to construct the plane, slant, and blade grid cathode. The material of the cathode and anode is CrNi18Ti9 and the ingredients of the electrolyte are 15% NaCl and 15% NaNO3. A large number of experiments are conducted by using different grid cathodes to analyze the effects of the shape and size of the grid cell on the machining process. In addition, we compare the workpiece quality and machining error between using the grid cathode and the unitary cathode and discuss the reasons for the errors in order to obtain a better surface quality of the workpiece. Our research supports the conclusions that the grid cathode can be used to manufacture workpieces with complex shapes, the workpiece quality is better if the square cell is smaller and, for the same equivalent area, the circular grid cathode produces a better quality workpiece than the square grid cathode.

Parameters Optimization and Experimental Study of Aero-Engine Blade in Electrochemical Machining Based on High-Risk Machining Parameter Elimination

2013 ◽  
Vol 567 ◽  
pp. 67-72 ◽  
Author(s):  
Zhi Yong Li ◽  
Zong Wei Niu ◽  
Li Li
Keyword(s):  
Electrochemical Machining ◽  
Parameters Optimization ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Object A ◽  
Parameter Combination ◽  
Aero Engine ◽  
Engine Blade ◽  
Blade Machining ◽  
Machining Parameter

Because the process of blade in electrochemical machining(EMC) can be effected by many factors, such as blade shapes, machining electrical field, electrolyte fluid field and anode electrochemical dissolution, different ECM machining parameters maybe result in great affections on blade machining accuracy. Regard some type of aero-engine blade as research object, a great deal of ECM machining parameter combination which probably result in machining failure can be eliminated based on BP neural network firstly. Furthermore, the optimized ECM machining parameter combination has been discovered. To verify the validity of the optimized ECM parameter combination, a serial of machining experiments have been conducted on an industrial scale ECM machine, and the experiment results demonstrates that the optimized ECM parameter combination not only can satisfy the manufacturing requirements of blade fully but has excellent ECM process stability.

Cathode Design of Aero-Engine Blades in Electrochemical Machining Based on Characteristics of Gap Distribution

2009 ◽  
Vol 69-70 ◽  
pp. 248-252 ◽  
Author(s):  
Ji Hua ◽  
Zhi Yong Li
Keyword(s):  
High Surface ◽  
Electrochemical Machining ◽  
Dimensional Accuracy ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Electrolyte Flow ◽  
High Surface Quality ◽  
Cathode Design ◽  
Aero Engine ◽  
Electric Filed

Cathode design is a difficult problem must be faced and solved in ECM. We develop a new numerical approach for cathode design by employing a finite element method and this approach has been applied in the cathode design of aero-engine blades in ECM. The mathematic models of the electric filed and electrolyte flow filed distribution in EMC process are described primarily. Then the realization procedure of this approach is presented，in which the effects of electric filed and electrolyte flow filed distribution within the inter-electrode gap domain are concentrated. In order to verify the machining accuracy of the designed cathodes, the experiments are conducted using an industrial scale electrochemical machining system. The experimental results demonstrate that the machined blade have high surface quality and dimensional accuracy which proves the proposed approach for cathode design of aero-engine blades in ECM is applicable and valuable.

Improvement of leading-edge accuracy by optimizing the cathode design plane in electrochemical machining of a twisted blade

2019 ◽  
Vol 234 (4) ◽  
pp. 814-824 ◽  
Author(s):  
Lingguo Yu ◽  
Dong Zhu ◽  
Yujun Yang ◽  
Jibin Zhao
Keyword(s):  
Three Dimensional ◽  
Electrochemical Machining ◽  
Leading Edge ◽  
The Body ◽  
Machining Process ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Cathode Design ◽  
Twisted Blade ◽  
Blade Leading Edge

Cathode design plays an important role in the electrochemical machining of aero engine blades and is a core issue influencing machining accuracy. Precision electrochemical machining of the leading edge of a twisted blade is particularly difficult. To improve the electrochemical machining accuracy of the leading edge, this article deals with cathode design by optimizing the design plane based on the three-dimensional potential distribution in the inter-electrode gap. A mathematical model is established according to the electrochemical machining shaping law, and the formation of the blade leading edge is simulated using ANSYS. The simulation results show that the blade leading-edge profile obtained with the optimized planar cathode is more consistent with the blade model profile. The optimized planar cathode and a non-optimized planar cathode are designed and a series of corresponding electrochemical machining experiments is carried out. The experiments show that the electrochemical machining process is stable and that the surface quality near the leading edge of the samples is slightly better than that of the body surface. Compared with the non-optimized planar cathode, the allowance difference at the leading-edge vertex is decreased by 0.062 mm. Using the optimized planar cathode allows fabrication of a workpiece whose shape is similar to that of the designed twisted blade.

Micro-ECM of Maze Flow Channel on Bipolar Plates of Fuel Cell

2010 ◽  
Vol 458 ◽  
pp. 125-130 ◽  
Author(s):  
Yuan Long Chen ◽  
H.B. Zhan ◽  
Shuo Jen Lee ◽  
S.M Zhu
Keyword(s):  
Fuel Cell ◽  
Pulse Current ◽  
Electrochemical Machining ◽  
Flow Channel ◽  
Machining Process ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Bipolar Plates ◽  
Flow Channels ◽  
Microsecond Pulse

A lot of flow channels should be processed on stainless steel bipolar plates of fuel cell. In order to increase contact area of gas with electrode and ensure the gas flowing smoothly, the flow channels will be multichannel maze. It is difficult to be machined by conventional methods, because the width and depth of the flow channels are very small (about 300μm). When using micro electrochemical machining, flow channels with low surface roughness and good machining accuracy could be produced efficiently. The machining cathode tool, fixture, μ-second grade pulse power supply and machining parameters are introduced. Using microsecond pulse current processing, the maze-shaped flow channel on bipolar plates of fuel cell can be processed seccessfully, with high efficiency and good quality. Thus graphite bipolar plates may be replaced by metal bipolar plates. It may promote the technology advancing for fuel cell, and reducing its cost. Key factors for influencing electrochemical machining process of flow Channels on bipolar plates include the design of cathode and fixture , microsecond pulse current, and suited technical parameters

Process Parameter Optimization and Experiment Study of Aero-Engine Blade in Electrochemical Machining

2010 ◽  
Vol 135 ◽  
pp. 418-423 ◽  
Author(s):  
Zhi Yong Li ◽  
Zong Wei Niu
Keyword(s):  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Parameter Combination ◽  
Fluid Field ◽  
Aero Engine ◽  
Engine Blade ◽  
Blade Machining ◽  
Temperature And Pressure ◽  
Machining Parameter

Because the process of blade in electrochemical machining(EMC) can be effected by many factors, such as blade shapes, machining electrical field, electrolyte fluid field and anode electrochemical dissolution, different ECM machining parameters maybe result in great affections on blade machining accuracy. Regard some type of aero-engine blade as research object, five main machining parameters, applied voltage, initial machining gap, cathode feed rate, electrolyte temperature and pressure difference between electrolyte inlet and outlet, have been evaluated and optimized based on BP neural network technique. From 3125 possible machining parameter combinations, 657 optimized parameter combinations are discovered. Furthermore, the final optimized ECM process parameters have been obtained. To verify the validity of the optimized ECM parameter combination, a serial of machining experiments have been conducted on an industrial scale ECM machine, and the experiment results demonstrates that the optimized ECM parameter combination not only can satisfy the manufacturing requirements of blade fully but has excellent ECM process stability.

Comparative Analysis of Flow Field in Mixed and Non Mixed Gas Electrochemical Machining for Aero-Engine Turbine Blade Cooling Holes

2017 ◽  
Vol 868 ◽  
pp. 166-171
Author(s):  
Zhing Yong Li ◽  
Xiu Ting Wei ◽  
Wen Wen Lu ◽  
Qing Wei Cui
Keyword(s):  
Flow Field ◽  
Flow Velocity ◽  
Turbine Blade ◽  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Mixed Gas ◽  
Turbine Blade Cooling ◽  
Blade Cooling ◽  
Vortex Zone ◽  
Aero Engine

By the cooling holes in aero-engine turbine blade as the research object, this study focuses on two kinds of ECM methods, which are mix gas added to the nonlinear electrolyte (NaNO3) and non-mixed gas. Mixed and non-mixed gas ECM experiments of turbine blade cooling holes were carried out respectively. The corresponding two-dimensional CAD model of cooling hole was constructed combined with the experimental data and theoretical analysis. Numerical simulation analysis was carried out of the flow field base on the above models by using the fluid dynamics analysis software FLUENT. The influence flow velocity and flow velocity distribution on the machining accuracy and efficiency of ECM were investigated in detail. The vortex zone distribution of gas-NaNO3 mixed phase flow field and single NaNO3 solution flow field was analyzed qualitatively. The simulation results indicated that the flow velocity in the machining gap with mixed gas was significantly higher than the velocity during ECM process for cooling holes. The electrolytic products and heat were washed away completely, the electrolyte can be updated in time. Fluid vortex zone distribution was improved obviously, the flow field distribution became more uniform after mixed gas in ECM process. The machining accuracy and efficiency for cooling holes making may be improved greatly with gas mixed in electrolyte NaNO3.

Fabrication of Micro Structures by Ultra Short Voltage Pulse Electrochemical Machining

2009 ◽  
Vol 419-420 ◽  
pp. 813-816 ◽  
Author(s):  
Hui Chen ◽  
Zhen Long Wang ◽  
Zi Long Peng ◽  
Wan Sheng Zhao
Keyword(s):  
Voltage Pulse ◽  
Electrochemical Machining ◽  
Pulse Frequency ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Stray Current ◽  
Micro Fabrication ◽  
Micro Hole ◽  
Micro Structures ◽  
Machining Localization

. The purpose of this paper is to study the application of electrochemical machining (ECM) technology for the fabrication of micro structures. The stray current corrosion, i.e. machining localization is a critical obstacle to micro fabrication for ECM. To machine micro structures by electrochemical machining ultra short voltage pulse is used. The effects of electrochemical machining parameters such as voltage, pulse duration, pulse frequency, and electrolyte composition on the machining accuracy were studied. In experiments, a micro hole was machined on stainless steel with cylindrical and square electrodes to investigate these effects.

The High Precision Blade Electrochemical Machining Simulation and Cathode Optimization Based on Isogeometric Method

2013 ◽  
Vol 339 ◽  
pp. 489-494 ◽  
Author(s):  
Ying Xiang ◽  
Rong Mo ◽  
Neng Wan ◽  
Hu Qiao
Keyword(s):  
Geometric Modeling ◽  
Design Method ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Simulation ◽  
Analysis Model ◽  
Simulation And Optimization ◽  
Nurbs Basis Function ◽  
Important Means ◽  
Optimization Efficiency

The simulation and optimization of electrochemical machining is an important means to improve processing quality. However, the fragmented nature of geometric modeling and numerical analysis model, restricts the application proportion. Aiming at this problem, it is refined that the scientific problem of coordination modeling between CAD and CAE based isogeometric method. In this paper, the unified model is established based NURBS basis functions to solve the problems that the geometric parameterization and the infliction of boundary conditions. And the optimization efficiency is promoted by improved optimization model using the convex hull characteristic of NURBS basis function. At last, a confluent design method is realized for the blade electrochemical machining process.

Sign in / Sign up

Export Citation Format

Share Document