The blade is a crucial component in an aero engine. In electrochemical machining of blades, the shaping law of the leading/trailing edge is intricate because of the complexity of the flow field and electric field distributions at these locations. This paper researches the formation of the leading/trailing edge. The dissolution process of the leading/trailing edge is simulated using an initial cathode and then its forecasted profile is obtained. The cathode is then adjusted according to the deviations between the forecasted profile and the model. Meanwhile, a coefficient between the deviations and the corrected value of the cathode is obtained after optimization simulation and the optimal value is about 1.17. Then, an optimal cathode is acquired by using the optimal coefficient. In addition, the effects of the thermal and hydrogen generation are also considered. The temperature increases to 8.28 K and the bubble rate increases to 25.30% at the electrolyte outlet. Furthermore, verification experiments are performed with the optimal cathode. The results show that the margin edges are formed and the accuracy is 0.13 mm of the leading edge, while the allowance of the profile at the electrolyte outlet is larger than that at the inlet, which means that the bubble rate is dominant in the inter-electrode gap. The results indicate that the design method for the leading/trailing edge is appropriate and can be used for manufacturing other complex components such as blisks and diffusers.
Electrochemical machining Blade Trailing edge Leading edge Simulation
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This work is financially supported by the National Nature Science Foundation of China (51675271), the Jiangsu Science Fund for Distinguished Young Scholars (BK20170031), the Fundamental Research Funds for the Central Universities (NE2014104 and NE 2017003).
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