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Electrochemical machining on blisk cascade passage with dynamic additional electrolyte flow

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Abstract

Electrochemical machining (ECM), which allows the processing of complex and intricate shapes in difficult-to-machine materials, has become one of the preferred manufacturing approaches for nickel–alloy blisks. The electrolyte flow field in the channel is a key factor influencing processing stability and surface quality. In this paper, the flow distribution in the ECM process of a blisk cascade passage is simulated. Then, a new dynamic additional electrolyte flow mode is presented as a means to eliminate local poor fluid regions. Through optimizing the additional pressure of this flow mode, a uniform flow field is obtained. Furthermore, verification experiments were carried out, and the results show that the process is stable and that the surface roughness of the hub is reduced with dynamic additional electrolyte flow. This flow mode can also be used in the ECM process for other complex parts of aeronautical engines.

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics & Astronautics, Nanjing, 210016, China

    Dong Zhu, Juchen Zhang, Kuanglei Zhang, Jia Liu, Zhu Chen & Ningsong Qu

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  1. Dong Zhu
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  2. Juchen Zhang
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  3. Kuanglei Zhang
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  4. Jia Liu
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  5. Zhu Chen
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  6. Ningsong Qu
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Correspondence to Dong Zhu.

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Zhu, D., Zhang, J., Zhang, K. et al. Electrochemical machining on blisk cascade passage with dynamic additional electrolyte flow. Int J Adv Manuf Technol 80, 637–645 (2015). https://doi.org/10.1007/s00170-015-7043-0

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  • DOI: https://doi.org/10.1007/s00170-015-7043-0

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