AI Chat Paper
Discover the SciOpen Platform and Achieve Your Research Goals with Ease.
Search articles, authors, keywords, DOl and etc.
{{expandStatus?'Exit ':''}}Advanced Search
Titanium alloy TC4 is widely used as the material of aero-engine blade, which is a typical difficult-to-process material. Electrochemical machining (ECM) is the preferred processing technology for titanium alloy TC4 because it does not depend on the strength and hardness of the material itself, high processing efficiency, and good surface quality. In this paper, the flow field characteristics and experiments of ECM of titanium alloy TC4 twisted blades are studied. According to the characteristics of the blade itself, the lateral flow tangential inlet flow field and the corresponding complex fixture and tool electrode are designed. The theoretical and geometric models of the flow field simulation are established, and the finite element simulation analysis of the flow field is carried out. The results show that the electrolyte flow rate in the new flow field is high and evenly distributed, and there is no shortage of liquid and vortex defects, which can meet the needs of ECM. The experiments of ECM parameters optimization are carried out, and it is found that pulse frequency and duty cycle have a key effect on the surface quality of titanium alloy TC4 blade. The experimental results show that the machining process is very stable under the new flow field mode and optimized machining parameters. The surface of the titanium alloy TC4 blade is bright and without defects. The surface roughness of the concave and the convex are Ra 0.44 μm and Ra 0.47 μm, respectively. The profile accuracy of concave and convex were -0.008 ~ +0.057 mm and -0.002 ~ +0.059 mm, respectively.
Lei GP, Zhu D, Li JB. Optimization of flow field in electrochemical trepanning of integral cascades (Ti6Al4V). Chinese J. Aeronaut. 2022;35(10):354-364.
Hong Y, Sun C, Guo Q, et al. High-performance Ti6Al4V surface manufacture by laser carburising-assisted grinding. Tribol. Int. 2024;198:109912.
Xu ZY, Wang YD. Electrochemical machining of complex components of aero-engines: Developments, trends, and technological advances. Chinese J. Aeronaut. 2021;34(2): 28-53.
Wang YD, Xu ZY, Meng DM, et al. Study on surface roughness of large size TiAl intermetallic blade in electrochemical machining, J. Manuf. Process. 2022;76:1-10.
Geng TY, Xu ZY. Electrochemical discharge machining for fabricating holes in conductive materials: A review. J. Adv. Manuf. Sci. Technol. 2021;1(3) 2021006.
Wang YD, Xu ZY, Liu J, et al. Study on flow field of electrochemical machining for large size blade. Int. J. Mech. Sci. 2021;190:106018.
Zhu D, Zhang J, Zhang K, et al. Electrochemical machining on blisk cascade passage with dynamic additional electrolyte flow. Int. J. Adv. Manuf. Technol. 2015;80:637-645.
Guo JW, Zhu D, Zhu D. Flow field design and experimental investigation of electrochemical machining on blisk. Chinese J. Aeronaut. 2022;35(8) 295-303.
Cao WJ, Wang DY, Guo HT, et al. Improvement on profile accuracy of convex structure during counter-rotating electrochemical machining by periodically changing electrolyte flow direction. J. Manuf. Process. 2023;102:79-94.
Xu ZY, Xu Q, Zhu D, et al. A high efficiency electrochemical machining method of blisk channels. CIRP Ann. - Manuf. Technol. 2013:62:187-190.
Chen XL, Ye ZS, Li GJ, et al. Electrochemical milling of deep-narrow slots with a pulsating electrolyte flow field. CIRP J. Manuf. Sci. Technol. 2022;39:244-260.
Yue XK, Qu NS, Niu S, et al. Improving the machined bottom surface in electrochemical mill-grinding by adjusting the electrolyte flow field. J. Mater. Process. Technol. 2020;276:116413.
Deng X, Zhang Y, Zhou X, et al. Mass transfer enhancement through trapezoidal anode in dynamic mask electrodeposition of metal micropillar. J. Adv. Manuf. Sci. Technol. 2024;4:1-12.
Jiang T, Zhu D, Lei GP. Electrochemical trepanning with an auxiliary electrode. Chinese J. Aeronaut. 2021;34(5):183-194.
Wang DY, Cao WJ, He B. Formation of a convex structure during the counter-rotating electrochemical machining of TC4 titanium alloy in NaCl solution. Int. J. Electrochem. Sci. 2019;14:9042-9057.
Wang ML, Qu NS. Investigation on material removal mechanism in mechano-electrochemical milling of TC4 titanium alloy. J. Mater. Process. Technol. 2021;295:117206.
Zhu HJ. FLUENT CFD engineering simulation practical guide. Beijing: Posts and Telecom Press;2014.
This is an Open Access article distributed under the terms of the Creative Commons Attribution License http://creativecommons.org/licenses/by/4.0)，which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
京公网安备11010802044758号