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

Abstract:

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.

• Periodical: Advanced Materials Research (Volumes 97-101)
• Pages: 3583-3586
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.97-101.3583
• Online since: March 2010
• Authors: Zhi Yong Li, Hua Ji
• Keywords: Cathode Design, Electrochemical Machining (ECM), Normal Gap Distribution, Three-Dimensional

References

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26 Normal gap (mm) Blade shape coordinate (mm) 0 2 4 6 8 10.

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26 Normal gap (mm) Blade shape coordinate (mm) 0 2 4 6 8 10.

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26 Normal gap (mm) Blade shpae coordinate (mm) 2D Normal Gap 3D Normal Gap 2D Normal Gap 3D Normal Gap 3D Normal Gap 2D Normal Gap Fig. 4 Comparison of two and three dimension normal gap (a) Section 1 (b) Section 2 (c) Section 3 Fig. 5 The designed cathode shape Fig. 6 Samples of machined aero-engine blades.

DOI: 10.11606/t.5.2005.tde-19032007-091334