To ensure the dimensional accuracy of the final blade profile, it is necessary for precision Electrochemical Machining (ECM) of blade profile to come into an equilibrium state. However, after Electrochemical Trepanning (ECTr), the cascade channel of the blisk is narrow, and the blank allowance distribution is uneven, making it difficult for the precision ECM to become balanced. In blisk production, the two-step method cannot make precision ECM enter equilibrium for some blisk types. A three-step processing method is proposed to overcome this problem. The three-step method adds Electrochemical Homogenizing Machining (ECHM) between the ECTr and precision ECM steps so that the blank allowance can be homogenized quickly without unduly affecting the minimum allowance. Comparative machining experiments of the two- and three-step methods were performed to verify the improvement to blade machining accuracy. The processing results show that the contour parameters of the blade after the three-step method implementation are much better. The allowance difference of the concave (convex) side decreased by 70.5% (65%). In addition, the current in the three-step method is stable at 110 A at the end of precision ECM, verifying successfully entering the equilibrium state.

The counter-rotating electrochemical machining (CRECM) shows unique potential in the machining of thin-walled rotating parts with complex convex structures. CREM realizes the shaping of complex convex structures through the relative rotation of the cathode and anode. The complex motion pattern and electric field distribution make it difficult to apply the existing cathode design methods to CRECM. To solve this problem, the matrix equations of cathode motion based on the kinematics and the electric field simulation model are established. The motion trajectories and edge contours at different angles are analyzed. The rotational overlap theory of motion trajectories under the windows at different angles is proved. Besides, the relationship between electric field distribution and the convex structure forming under different angle windows is studied, and the fundamental reason for deviations occurs when the convex profile is rotated to coincide is revealed. Therefore, a prediction model of the sidewall dissolution is established to correct this deviation, thereby deriving a high-precision design formula for the cathode windows of the high convex structures. By designing a cathode with oval-like windows to curry out CRECM experiments, the array-arranged (30 × 5) circular high convex structure with a maximum roundness error of 0.065 mm is successfully fabricated.

The blisk is a core component of an aero-engine, and electrochemical machining (ECM) is the primary method for its manufacture. Among several ECM methods for blisks, multi-tool synchronous machining is the most efficient and advantageous for machining channels. The allowance distribution of the blank after blisk channel machining directly influences the blade profile accuracy. This paper proposes a trajectory control strategy to homogenize the allowance distribution of the blisk channel in multi-tool ECM. The strategy includes the design of the three-dimensional space motion of the tool and blisk, as well as the regulated feed speed. The structural characteristics of the blisk channel and the principle of ECM allow for designing and optimizing the multi-dimensional trajectory. The electric field simulations elucidate the influence law of the three-axis feed speed on the side gap. An algorithm is adopted to iteratively optimize the speeds for different positions to realize multi-dimensional motion control and allowance homogenization. The proposed trajectory control strategy is applied to ECM experiments for the blisk channel. Compared with the constant feed speed mode, the regulated speed strategy reduces the maximum allowance difference between the convex (CV) profiles by 36.18% and that between the concave (CC) profiles by 37.73%. Subsequently, the one-time ECM of eight blisk channels was successfully realized. The average time for a single channel was 12.5 min, significantly improving the machining efficiency. In conclusion, the proposed method is effective and can be extended for synchronously machining various blisk types with twisted channels.

To obtain final parts with the desired dimensional accuracy and repeatability via electrochemical machining (ECM), the machining process must enter an ECM balanced state. However, for the ECM processing of blisk, a key component of aerospace engines, the surface of the blade blank often has an uneven allowance distribution due to the narrow passage of the cascade. It is difficult to remedy this issue in subsequent processing steps, which is necessary to ensure the dimensional accuracy and repeatability of the final blade profile. To solve this problem, electrolytic machining must be preceded by electrolytic shaping, which requires cathode tools with large leveling ratios to quickly homogenize the blank surface of the blade. In this study, to obtain a cathode tool with an extremely high leveling ratio, a design method based on the variation in the electrode gap in the non-equilibrium electrolytic state is proposed, and a dissolution model based on the non-equilibrium state is established. In this design method, the allowance on the blank to be machined is first divided into many discrete allowances with the normal direction. The initial machining clearance, feed rate, and total machining time are then calculated using classical ECM equilibrium state theory based on the maximum allowance. Meanwhile, the point coordinates of the cathode tool at maximum allowance can be determined. The non-equilibrium model can then be used to calculate the relative coordinate positions corresponding to the remaining discrete allowances. Finally, the entire cathode tool profile is designed. Simulations, fundamental experiments, and blisk unit workpiece experiments were carried out to validate the design approach. In the simulated processing of the plane workpiece, the leveling ratio of the cathode tool designed by the proposed method (0.77) was 83% higher than that of the cathode tool designed using the traditional method. The simulation results were confirmed by processing experiments. In the machining of blisk unit workpieces with complex curved surfaces, the leveling ratios of the convex and concave parts of the blade machined using the proposed cathode tool respectively reached 0.75 and 0.54, which are 75% and 38% higher than those obtained using the traditional method. This new cathode design method and machining technology can significantly improve the surface allowance distribution of blank before electrolytic finishing. It is helpful for finishing machine to enter electrolytic equilibrium state. Finally, the final blade profile accuracy can be guaranteed and repeated errors can be reduced.

Electrochemical machining (ECM) has emerged as an important option for manufacturing the blisk. The inter-electrode gap (IEG) distribution is an essential parameter for the blisk precise shaping process in ECM, as it affects the process stability, profile accuracy and surface quality. Larger IEG leads to a poor localization effect and has an adverse influence on the machining accuracy and surface quality of blisk. To achieve micro-IEG (<50 μm) blisk finishing machining, this work puts forward a novel variable-parameters blisk ECM strategy based on the synchronous coupling mode of micro-vibration amplitude and small pulse duration. The modelling and simulation of the blisk micro-IEG machining have been carried out. Exploratory experiments of variable-parameters blisk ECM were carried out. The results illustrated that the IEG width reduced with the progress of variable parameter process. The IEG width of the blade’s concave part and convex part could be successfully controlled to within 30 μm and 21 μm, respectively. The profile deviation for the blade’s concave surface and convex surface are 49 μm and 35 μm, while the surface roughness reaches R_a = 0.149 μm and R_a = 0.196 μm, respectively. The profile accuracy of the blisk leading/trailing edges was limited to within 91 μm. Compared with the currently-established process, the profile accuracy of the blade’s concave and convex profiles was improved by 50.5 % and 53.3 %, respectively. The surface quality was improved by 53.2 % and 50.9 %, respectively. Additionally, the machined surface was covered with small corrosion pits and weak attacks of the grain boundary due to selective dissolution. Some electrolytic products were dispersed on the machined surface, and their components were mainly composed of the carbide and oxide products of Ti and Nb elements. The results indicate that the variable-parameters strategy is effective for achieving a tiny IEG in blisk ECM, which can be used in engineering practice.