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| 1 | 脉动态电解加工显示文摘电解加工在航空航天装备的核心部件制造中起到了重要作用。为了满足这些高科技产品的发展需求,它的加工精度需要进一步提高。电解加工过程中产生的氢气、温升及去除物,会显著影响加工间隙中电解液电导率的分布,并降低加工精度。脉动态电解加工将工具振动与脉冲给电优化耦合,改变了间隙状态,提高了精度和稳定性。拷贝式、旋印式、削边电极线切割式等3种脉动态电解加工形式分别对应叶片类、机匣类、榫槽类结构的加工表现出很好的工艺效果。 | 朱荻 刘嘉 王登勇 房晓龙 刘言 | 2022 | 航空学报2022，43，4： | 7 |
| 2 | Electrode design using revolving entity extraction for high-efficiency electric discharge machining of integral shrouded blisk显示文摘The integral shrouded blisk provides better performance with minimum weight,but its semi-open structure presents problems for its production.Manufacturing processes of these components require a removal of about 70%-90%of material from their blanks.Multi-axis electrical discharge machining(EDM)is commonly used for these processes,but its poor efficiency cannot meet the requirements of mass production.Strong flushing assisted high-current discharge is able to improve the machining efficiency.In this paper,this method was applied to manufacture the integral shrouded blisk.An electrode design method was proposed.Taking the largest revolving entity inside the flow channel as the base geometry,this laminated arc-shaped hollow electrode meets the requirements such as high pressure flushing,tool wear compensation,and easy to be made.A 4-axis linkage machining tool path with planetary motion was proposed.Taking an integral guide vane ring as an example,it has been experimentally verified that the time consumption for each channel using this method was reduced to a half of the ordinary EDM method,while the finished surface quality remains same. | Yuchao JIA Guanxin CHI Yang SHEN Kun ZHANG Zhenlong WANG Yukui WANG | 2021 | Chinese Journal of Aeronautics2021，34，6： | 5 |
| 3 | 闭式整体叶盘成组电极高效电弧成形加工技术显示文摘带叶冠的闭式整体叶盘可为液体火箭发动机涡轮泵、航空涡轮发动机等产品提供优异性能,但更高的加工难度也成为制约加工成本和生产能力的瓶颈。目前通常采用电火花加工、电化学加工工艺加工该类开敞性不足的闭式流道,主要问题在于加工效率较低,制造成本昂贵。为此,提出一种使用成组电极在大电流、长脉宽放电条件下进行多流道并行开粗加工的高效电弧加工方法。首先分析了高效电弧放电加工对成组电极设计的要求,提出一种具有内冲液结构的多头成组电极设计方法,然后借助流体仿真工具对电极内部冲液通道的分流结构进行了优化设计。通过试制一款闭式整体叶环,对该方法实际效果进行了验证,测算了加工过程的材料去除率、电极损耗率。结果显示,与此前提出的单头电极电弧加工相比,使用该成组电极后材料去除率提高了62.9%。得益于更高的材料去除率和更少的辅助操作,同款叶盘的开粗用时缩短为常规电火花加工工艺的8.7%。 | 贾雨超 迟关心 张昆 张甲 王振龙 | 2022 | 航空学报2022，43，4： | 3 |
| 4 | Electrochemical machining on blisk channels with a variable feed rate mode显示文摘Electrochemical machining(ECM)is an economical and effective method for blisk manufacturing and includes two steps:channel machining and profile machining.The allowance distribution after the channel machining will directly affect the profile machining.Therefore,to improve the uniformity of allowance distribution in the machining of channels,a method that incorporates a variable feed rate mode is developed.During the machining process,the feed rates are dynamically changed according to the needs of the side gap at the different feed depths.As a result,the side gaps at the different feed depths vary,contributing to a decrease in the allowance difference.In this study,the dissolution processes of a blisk channel are simulated using different feed rates,and prediction profiles are obtained.Based on the prediction profiles,the relationship among the feed rate,feed depth,and side gap is established.Then,the feed rates at different feed depths are adjusted according to the relationship.In addition,contrast experiments are conducted.Compared with blisk channel ECM using a constant feed rate of 1 mm/min,using the variable feed rate decreases the allowance differences in the convex and concave parts by 62.2%and 67.4%,respectively.This indicates that using the variable feed rate in the ECM process for a blisk channel is feasible and efficient. | Jing WANG Zhengyang XU Jingtao WANG Di ZHU | 2021 | Chinese Journal of Aeronautics2021，34，6： | 2 |
| 5 | 航空发动机叶片脉动分步精密电解加工方法研究显示文摘电解加工在欧美航空发动机叶片或整体叶盘等核心部件的高效、精密制造中起到了重要作用。传统叶片电解加工模式中,叶盆工具电极和叶背工具电极相向运动,同时加工出叶型和进排气边轮廓,此时叶型精度易保证而进排气边精度低。提出了叶片脉动分步精密电解加工方法,旨在进一步提高叶身型面精度的同时提升进排气边轮廓精度。叶片电解加工分为两个不同的阶段,首先通过脉动态变参数模式进行叶身型面精密电解加工,其次利用微量脉冲电解模式进行进排气边的切向电解加工。阐述了脉动态变参数加工方法和进排气边微量脉冲切向加工方法在成型机理和工艺试验等方面的研究,并针对传统径向流场中存在被动分流的问题,提出了主动分流式径向流场。试验结果表明,提出的精密电解加工方法表现出很好的工艺效果,叶盆型面和叶背型面的轮廓度加工误差分别为–0.013~0.025 mm和–0.003~0.030 mm,进气边轮廓度加工误差为–0.034~0.041 mm,排气边轮廓度加工误差为–0.038~0.034 mm,叶盆型面和叶背型面的表面粗糙度分别为R0.333μm和R0.287μm。提出的方法为实现航空发动机叶片的高精度制造提供了新的解决途径,并可用于其他复杂型面类部件的电解加工。 | 徐正扬 王京涛 刘嘉 朱栋 魏浩迪 | 2022 | 航空制造技术2022，65，17： | 1 |
| 6 | Effect of assisted transverse magnetic field on distortion behavior of thin-walled components in WEDM process显示文摘Machining performance of thin-walled components made by aeronautical difficult-toprocess materials is a significant issue in the aviation manufacturing industry.Although wire electric discharge machining-low speed(WEDM-LS)is one of typical non-contact machining processes without macro cutting force,which does well in removing hardness and brittleness materials via pulsed discharge at high temperature,but few researchers have studied the thermal distortion behavior leading to a considerable geometric error in the WEDM-LS of thin-walled components.In this paper,a transverse magnetic field assisted method is applied for affecting the uniformity of discharge point distribution so as to reduce the distortion in WEDM-LS processing thin-wall component.First,the generation mechanism of this new distortion behavior and the impact mechanism of transverse magnetic field(TMF)on distortion are demonstrated by theoretical analysis.In order to further figure out the distortion behavior in the TMF-WEDM process,a new thermophysical model considering the discharge point distribution is established to simulate temperature field,residual stress field and distortion profiles.Then a large number of Taguchi experiments are carried out to investigate the influences of process parameters including pulse discharge energy(pulse on time,pulse off time,and current)and magnetic field strength on distortion in WEDM-LS.To comparatively analyze simulated and experimental results,the accuracy of established thermophysical model is verified within a relative error of 18.38%in distortion.Moreover,it can be revealed that transverse magnetic field contribute to significantly improve the longitudinal distribution uniformity with maximum increase of 12.32%at magnetic field strength:0.15 T,leading to significant reductions of 32.77%in distortion and 22.68%in recast layer.Eventually,we also presented the variation of residual stress and recast layer along thickness direction under different distortion behavior,which are in good agreement with that of distortion behavior. | Yanming ZHANG Guojun ZHANG Zhen ZHANG Yi ZHANG Yu HUANG | 2022 | Chinese Journal of Aeronautics2022，35，2： | 1 |
| 7 | Ti48Al2Cr2Nb合金高电位腐蚀的电流时间序列相空间重构分析显示文摘采用相空间重构法,研究Ti48Al2Cr2Nb合金在高电位电化学腐蚀过程中电流密度时间序列的动力学演化特征。结果表明:电化学系统均存在相似结构的吸引子,其轨迹线均分布在45°对角线上,随着时间以一定规律反复折叠和拉伸,且随着电位的提升越来越复杂、光滑,填充区域变大。结合腐蚀形貌可知,吸引子的具体形态与合金在相应电位下的腐蚀行为密切相关:低电位下电流密度较低,合金的腐蚀以点蚀和不均匀的片层溶解为主,吸引子轨迹线不光滑、占有区域小;随着电位增加、电流密度增大,合金的腐蚀行为逐渐以均匀溶解为主,吸引子轨迹线占有区域大,轨迹线较光滑。 | 张显苗 罗志坚 廖翠姣 | 2022 | 电加工与模具2022，，2： | 1 |
| 8 | Dependency of the pulsed electrochemical machining characteristics of Inconel 718 in NaNO_(3)solution on the pulse current显示文摘Pulsed electrochemical machining(PECM)has attracted increasing interest as a technique to improve material dissolution localization and surface quality.This work systematically investigates the effects of pulse current on the surface morphology,profile accuracy,and corrosion behavior of Inconel 718(IN718)in NaNO_(3)solution.Polarization behavior reveals that IN718 in NaNO_(3)solution during pulse current machining exhibited significant passive,transpassive,and re-passive characteristics.The passive film generated at the re-passive state contained some oxides and had a loose porous structure.The critical value for the quantity of electric charge to rupture the passive film was determined to be 26.88℃cm^(−2).The current efficiency indicates that the material removal rate of IN718 in NaNO_(3)solution during pulse current machining was nonlinear.The PECM experiments indicate that the loading process of the electrical double layer was prolonged with an increased workpiece scale,i.e.,the loading process of the electrical double layer lasted for the entire pulse-on time when the workpiece scale was 100 mm^(2)at a frequency of more than 10 kHz regardless of the duty cycle.A pulse current with a short pulse length and short pulse period improved the profile accuracy,as did the low applied voltage and small workpiece scale.The dissolution mechanism of IN718 in NaNO_(3)solution was also investigated based on the effective pulse current time.Finally,the leading-edge structure of a ruled blade with good dimensional accuracy and surface quality was successfully fabricated.The maximum deviations of the machined profile were effectively restricted within 0.057 mm,and the surface roughness was Ra=0.358μm. | WANG JingTao XU ZhengYang GENG TianYu ZHU Di | 2022 | Science China(Technological Sciences)2022，65，10： | 1 |
| 9 | 射流电解铣削加工微槽试验研究显示文摘针对管电极射流电解铣削加工微槽进行了工艺参数试验研究,结果表明:当其他加工参数不变时,单次加工的微槽尺寸与电流密度成正相关,与进给速度成负相关,多次重复加工微槽可有效增大槽深,但槽宽几乎不变。在此基础上,建立了槽宽和槽深关于电流密度与进给速度的经验公式,以及槽深关于重复加工次数的经验公式,并通过实验验证了经验公式的可行性。 | 温帆帆 曲宁松 | 2022 | 电加工与模具2022，，S01： | 0 |
| 10 | 叶盘叶栅多管电极电解加工流场均匀性研究显示文摘多管电极电解加工可在一次进给过程中同时加工整体叶盘的多个叶栅通道,然而多管电极加工中常出现电解液分流不均问题,导致个别电极加工区缺液而引起短路。为实现多管电极稳定加工,提出了一种多叶栅通道电解液流量控制方案,在加工过程中对进入每一叶栅通道的电解液流量实时监测调节,实现多叶栅通道加工电解液流量均匀一致。基于该方案,开展整体叶盘扇段多叶栅通道电解加工试验,成功实现了整体叶盘扇段7个叶栅通道同时电解加工。试验结果表明:各叶栅通道电解液流量均匀一致,加工所得的工件重复度和精度高,并显著提高了叶栅通道的加工效率。 | 宗亚伟 刘嘉 朱荻 | 2021 | 电加工与模具2021，，5： | 0 |
| 11 | 电解加工对GH4169G高温合金表面完整性和力学性能的影响显示文摘对比了机械加工和电解加工对GH4169G高温合金表面完整性和力学性能的影响。结果显示,经过电解加工的GH4169G高温合金表面不存在明显的晶粒细化或破碎的变形层,其在深度方向的表面残余应力变化幅度较小,基本保持在100 MPa以内。电解加工试样的高温持久性能与机械加工试样相当,前者的室温振动疲劳寿命低于后者,可能与电解加工试样的表面粗糙度较高有关,但都在同一数量级。 | 詹中伟 刘嘉 孙志华 李海扬 汤小军 | 2022 | 电镀与涂饰2022，41，6： | 0 |
| 12 | 基于双质体振动的水平激振抛磨设备动力学分析显示文摘对一种用于复杂型腔激振抛磨的水平双质体振动设备的动力学特性进行了研究。首先建立了该设备的动力学模型,运用Lagrange方程推导其运动微分方程,并求解得到双质体的稳态位移响应;其次采用Runge-Kutta算法进行数值仿真,得到的幅频响应规律与计算结果基本一致,即双质体振动设备在38~40 Hz时出现反共振点、在45 Hz以上时设备发生共振;随后分析了结构参数对设备动力学特性的影响,结果表明,参振质量、激振力和主振弹簧刚度对水平双质体振动设备的运动特性产生较为明显的影响;最后对样机进行了实验测试,并采用FIR低通滤波处理了测得的振动信号,实验结果进一步验证理论分析与数值仿真的有效性。研究结果对不同型号机匣型腔的激振抛磨提供了工作参数选择,同时也为相关振动设备的研发设计提供了理论基础与方法。 | 黄辉 郝玉鹏 杨胜强 李东祥 王进军 | 2023 | 现代制造工程2023，，10： | 0 |
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