Optimization and Affections of Cathode Feed Angle on Machining Accuracy Error Distribution of Aero-Engine Blade in Electrochemical Machining

2018 ◽  
Vol 764 ◽  
pp. 225-234 ◽  
Author(s):  
Zhi Qiang Zhao ◽  
Zhi Gang Ma ◽  
Yue Tao Liu ◽  
Xiao Long Wu ◽  
Hun Guo
Keyword(s):  
Electrochemical Machining ◽  
Error Distribution ◽  
Optimal Combination ◽  
Experimental Results ◽  
Machining Accuracy ◽  
Machining Error ◽  
Feed Angle ◽  
Aero Engine ◽  
Engine Blade ◽  
Blade Shape

Utilizing all-direction electrochemical machining (ECM) for super-thin twist aero-engine, feed angle of tool cathode and blade fixture angle are investigated and optimized in this study. The most optimal combination of the two angles (oblique feed angle of tool cathode and fixture angle of blade stock) is selected from all 65341 angle combinations. Moreover, the affections of the optimized angle combination on machining error distribution between blade shape and plate are concentrated. The analysis and experimental results demonstrate that the optimized angle combination can satisfy the machining requirements of blade shape and error distribution of blade shape and plate.

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.

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.

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.

scholarly journals Surface Fitting for non-Grid Data from in-Situ Measuring Systems of Aero-engine Blade

2020 ◽  
Vol 206 ◽  
pp. 03023
Author(s):  
Qing Mao ◽  
Sen Wang ◽  
Shugui Liu
Keyword(s):  
Dynamic Performance ◽  
Surface Fitting ◽  
Data Conversion ◽  
Machining Accuracy ◽  
Nurbs Surface ◽  
Grid Data ◽  
Measuring Systems ◽  
Aero Engine ◽  
Engine Blade

High machining accuracy of aero-engine blade largely determines the carrying capacity, endurance, acceleration and the dynamic performance of the aero-engine, so a reliable machining error inspection and evaluation technique is imperative. In order to give a reliable error evaluation, the non- uniform rational B-spline (NURBS) technique is adopted to reconstruct the surface within a specified accuracy. Usually, data points measured from aero-engine blade are non-grid data in situ measuring systems. To overcome the difficulty of NURBS surface fitting from non-grid data, a new method based on data conversion is proposed, in which chord length parameterization and uniform parameter sampling are combined together to realize the data convertation, and subsequently hierarchical fitting strategy is applied to finish the NURBS surface reconstruction. The way proposed for data conversion is easy to realize, and by which gemetrical features of original measured data are also reserved well, which make the whole method outstanding in low time cost. Experimental results show that the method is fast, effective. The source code has been implemented in VC++, while the resulting pictures are constructed in Matlab with the obtained control points, knot vectors, and the orders.

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.

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.

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.

Electrochemical Machining of the Turbulated Hole

2010 ◽  
Vol 97-101 ◽  
pp. 4088-4091
Author(s):  
Ming Huan Wang ◽  
C.Y. Yao ◽  
Qiao Fang Zhang ◽  
Wei Peng
Keyword(s):  
Power Supply ◽  
System Analysis ◽  
Electrochemical Machining ◽  
Experimental System ◽  
Power Supply Unit ◽  
Experimental Results ◽  
Machining Efficiency ◽  
Complex Profile ◽  
Machining Error ◽  
Holding Device

Electrochemical machining (ECM) technology has the advantage of machining the workpiece with complex profile on the basis of electrolysis. In this study, turbulated holes with the rib’s shape of spiral and annular were processed by ECM by using the shaped cathodes. Experimental system was built which consists of electrolyte supply module, power supply unit and workpiece holding device. Machining experimentations were carried out on the built system. Analysis and discussions were done according to the experimental results. It indicated machining efficiency is high by using the shaped cathode. Machining error could be controlled within 10-20%.

scholarly journals Multiscale Modeling and Simulation of Directional Solidification Process of Ni-Based Superalloy Turbine Blade Casting

Metals ◽  
2018 ◽  
Vol 8 (8) ◽  
pp. 632 ◽  
Author(s):  
Qingyan Xu ◽  
Cong Yang ◽  
Hang Zhang ◽  
Xuewei Yan ◽  
Ning Tang ◽  
...  
Keyword(s):  
Directional Solidification ◽  
Grain Growth ◽  
Turbine Blade ◽  
Turbine Blades ◽  
Solidification Process ◽  
Experimental Results ◽  
Directional Solidification Process ◽  
Grain Structures ◽  
Aero Engine ◽  
Engine Blade

Ni-based superalloy turbine blades have become indispensable structural parts in modern gas engines. An understanding of the solidification behavior and microstructure formation in directional solidified turbine blades is necessary for improving their high-temperature performance. The multiscale simulation model was developed to simulate the directional solidification process of superalloy turbine blades. The 3D cellular automaton-finite difference (CA-FD) method was used to calculate heat transfer and grain growth on the macroscopic scale, while the phase-field method was developed to simulate dendrite growth on the microscopic scale. Firstly, the evolution of temperature field of an aero-engine blade and a large industrial gas turbine blade was studied under high-rate solidification (HRS) and liquid-metal cooling (LMC) solidification processes. The varying withdrawal velocity was applied to change the curved mushy zone to a flat shape. Secondly, the grain growth in the aero-engine blade was simulated, and the grain structures in the starter block part and the spiral selector part in the HRS process were compared with those in the LMC process. The simulated grain structures were generally in agreement with experimental results. Finally, the dendrite growth in the typical HRS and LMC solidification process was investigated and the simulation results were compared with the experimental results in terms of dendrite morphology and primary dendritic spacing.

ANALYSIS OF THE ACCURACY OF ELECTROMECHANICAL MICROMACHINING

2020 ◽  
pp. 60-64
Author(s):  
Yu.A. Morgunov ◽  
B.P. Saushkin ◽  
N.V. Homyakova
Keyword(s):  
Electrochemical Performance ◽  
Electrochemical Machining ◽  
Machining Error ◽  
Processing Mode ◽  
Primary Error ◽  
Flow Through ◽  
Relative Errors ◽  
Size Tolerance

The achieved accuracy in the electrochemical performance of understatement with a depth of 18 mcm with a tolerance of 4.5 mcm in a flow-through interelectrode channel is studied. The primary error of the size. The allowed absolute and relative errors of processing mode parameters are set. Keywords: UNDERSTATEMENT, ELECTROCHEMICAL MACHINING, ERROR, PRECISION SIZE, TOLERANCE, PROCESSING MODE. [email protected]

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