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Simulation and experiment research on liquid channel of diffuser blade by electrochemical machining

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Abstract

Aiming to solve the problems of the low electrolyte flow rate at leading edge and trailing edge and poor uniformity of the end clearance flow field during the electrochemical machining (ECM) of diffuser blades, a gap flow field simulation model was established by designing three liquid-increasing channels at the leading edge and the trailing edge of the cathode. The simulation results indicate that the liquid-increasing hole channel (LIHC) with an outlet area S of 1.5 mm2 and a distance L from channel center to edge point of 3.2 mm achieves optimal performance. In addition, the experiment results show that the optimized cathode with liquid-increasing hole channel (LIHC) significantly improves the machining efficiency, accuracy, and surface quality. Specifically, the feed speed increased from 0.25 mm/min to 0.43 mm/min, the taper decreased from 4.02° to 2.45°, the surface roughness value of the blade back reduced from 1.146 to 0.802 µm. Moreover, the roughness of the blade basin decreased from 0.961 to 0.708 µm, and the roughness of the hub reduced from 0.179 to 0.119 µm. The results prove the effectiveness of the proposed method and can be used for ECM of other complex structures with poor flow field uniformity.

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Funding

This work was supported by the National Natural Science Foundation of China (U19A20103); The Fund for Jilin Province Scientific and Technological Development Program (No. Z20190101005JH); The Fund for The Central Government Guides Local Science and Technology Development Funds to the special basic research of Jilin Province (No. 202002039JC).

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Authors and Affiliations

  1. Ministry of Education Key Laboratory for Cross-Scale Micro and Nano Manufacturing, Changchun University of Science and Technology, Changchun, 130022, China

    Jinkai Xu, Jin Tao, Wanfei Ren, Kun Tian, Xiaoqing Sun & Huadong Yu

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  1. Jinkai Xu
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  2. Jin Tao
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  3. Wanfei Ren
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  4. Kun Tian
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  5. Xiaoqing Sun
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Contributions

Jinkai Xu and Wanfei Ren were responsible for substantive revision; Jin Tao drafted the manuscript and performed the experiments; Kun Tian assisted in the experiment; Xiaoqing Sun performed the interpretation of the data; Huadong Yu contributed to the design of the work.

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Correspondence to Jinkai Xu or Wanfei Ren.

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Xu, J., Tao, J., Ren, W. et al. Simulation and experiment research on liquid channel of diffuser blade by electrochemical machining. Int J Adv Manuf Technol 119, 6045–6056 (2022). https://doi.org/10.1007/s00170-021-08497-y

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  • DOI: https://doi.org/10.1007/s00170-021-08497-y

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