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| 1 | 变截面异型螺旋型腔电解加工流场分析显示文摘针对闭式整体构件电解加工间隙流场分布不均匀的,基于电解加工间隙流场,设计了阴极过水孔工作端面,比较了不同背压条件下电解加工间隙流场,分析了间隙流场空穴、涡流现象.研究结果表明,通过改变过水孔分的疏密,孔径的大小和形状,增加背压,消除了间隙流场中低流速区域,电解液较低流速区域的速度由0.239 7m/s提升至0.508 5m/s,减少了空穴和涡流现象的发生,优化了阴极结构. | 范植坚 穆倩 李清良 范庆明 | 2014 | 西安工业大学学报2014，34，2： | 5 |
| 2 | Cathode design investigation based on iterative correction of predicted profile errors in electrochemical machining of compressor blades显示文摘Electrochemical machining(ECM) is an effective and economical manufacturing method for machining hard-to-cut metal materials that are often used in the aerospace field. Cathode design is very complicated in ECM and is a core problem influencing machining accuracy, especially for complex profiles such as compressor blades in aero engines. A new cathode design method based on iterative correction of predicted profile errors in blade ECM is proposed in this paper. A mathematical model is first built according to the ECM shaping law, and a simulation is then carried out using ANSYS software. A dynamic forming process is obtained and machining gap distributions at different stages are analyzed. Additionally, the simulation deviation between the prediction profile and model is improved by the new method through correcting the initial cathode profile. Furthermore, validation experiments are conducted using cathodes designed before and after the simulation correction. Machining accuracy for the optimal cathode is improved markedly compared with that for the initial cathode. The experimental results illustrate the suitability of the new method and that it can also be applied to other complex engine components such as diffusers. | Zhu Dong Liu Cheng Xu Zhengyang Liu Jia | 2016 | Chinese Journal of Aeronautics2016，29，4： | 5 |
| 3 | Shape evolution and prediction of three dimensional workpieces in electrochemical machining显示文摘Based on the Faraday’s Law, the shape evolution model was calculated depending on a function of time, and the influence of the variable current efficiency which was brought by the passivating electrolyte was included. The final shape determination was obtained by solving the model of electric-field distribution by the finite element method, at the same time flow parameters influencing on the shaping process were also considered. The results show that the experimental results are in close agreement with the theoretical ones. | 王蕾 朱荻 | 2005 | 中国有色金属学会会刊:英文版2005，15，S3： | 4 |
| 4 | Electrochemical trepanning with uniform electrolyte flow around the entire blade profile显示文摘In the traditional machining process for diffusers, blades are easily deformed, and methods suffer from high tool wear and low efficiency. Electrochemical machining(ECM) possesses unique advantages when applied to these difficult-to-machine materials. In the ECM process, theflow field plays a crucial role. Here, an electrolyte flow mode that supplies uniform flow around the entire blade profile was adopted for electrochemical trepanning of diffusers. Various flow rates were employed to obtain the optimal flow field. Simulations were conducted using ANSYS software, and results indicated that increasing the flow rate substantially afforded a more uniform flowfield. A series of experiments was then performed, and results revealed that increasing the flow rate greatly improved both the machining efficiency and the surface quality of the diffusers. The maximum feeding rate of the cathode reached 4 mm/min, the blade taper of the concave part decreased to 0.02, and the blade roughness was reduced to 1.216 lm. The results of this study demonstrated the high feasibility of this method and its potential for machining other complex components for engineering applications. | Dong ZHU Tingyu XUE Xingyan HU Zhouzhi GU | 2019 | Chinese Journal of Aeronautics2019，32，7： | 3 |
| 5 | Flow field design and process stability in electrochemical machining of diamond holes显示文摘The metal grille, commonly composed of an amount of diamond holes, has been growingly used as a key structure on stealth aircraft. Electrochemical machining(ECM) promises to be increasingly applied in aircraft manufacturing on the condition that process stability is guaranteed.In this work, a flow field model was designed to improve the process stability. This model is endowed with a variety of flow channel features, together with vibrating feeding modes. The flow field distribution on the bottom surface of the diamond hole was discussed and evaluated as well.The numerical results show that a short arc flow channel could significantly enhance the uniformity of electrolyte velocity distribution and a vibrating feeding of the cathode enables to reduce both fluctuations of the electrolyte velocity and pressure on the bottom surface of the diamond hole.Consequently, the flow field mutations were eliminated. It is verified from the experimental results that a short arc flow channel, when combined with vibrating feeding, is capable of improving machining localization and process stability markedly. What is more, the side gap on the bottom surface of the diamond hole could also be reduced by the abovementioned approach. | Zhao Jianshe Wang Feng Liu Zhuang Zhang Xiangli Gan Weimin Tian Zongjun | 2016 | Chinese Journal of Aeronautics2016，29，6： | 3 |
| 6 | Effect of tube-electrode inner diameter on electrochemical discharge machining of nickel-based superalloy显示文摘Nickel-based superalloys are widely employed in modern aircraft engines because of their excellent material characteristics, particularly in the fabrication of film cooling holes. However, the high machining requirement of a large number of film cooling holes can be extremely challenging. The hybrid machining technique of tube electrode high-speed electrochemical discharge drilling(TEHECDD) has been considered as a promising method for the production of film cooling holes. Compared with any single machining process, this hybrid technique requires the removal of more complex machining by-products, including debris produced in the electrical discharge machining process and hydroxide and bubbles generated in the electrochemical machining process. These by-products significantly affect the machining efficiency and surface quality of the machined products. In this study, tube electrodes in different inner diameters are designed and fabricated, and the effects of inner diameter on the machining efficiency and surface quality of TEHECDD are investigated. The results show that larger inner diameters could effectively improve the flushing condition and facilitate the removal of machining by-products. Therefore, higher material removal efficiency, surface quality, and electrode wear rate could be achieved by increasing the inner diameter of the tube electrode. | Zhang Yan Xu Zhengyang Xing Jun Zhu Di | 2016 | Chinese Journal of Aeronautics2016，29，4： | 3 |
| 7 | Electrochemical Machining Analysis on Grid Cathode Composed of Square Cells显示文摘During the electrochemical machining (ECM), the cathodes designed by the existing methods are mainly unitary cathodes, which can be only used to produce the workpieces with the same shapes. However, there are few researches on designing cathodes for machining the different workpieces with the different surfaces. This paper presents the grid cathode composed of the square cells to produce the workpieces with different shapes. Three types of the square cells, 2.5 mm′2.5 mm, 3 mm′3 mm, and 4 mm′4 mm, are utilized to construct the plane, the slant, and the blade cathode. The material of the cathode and the anode is CrNi 18 Ti 9 , and the ingredient of electrolyte is 15% NaCl and 15% NaNO 3 . The machining equilibrium machining current and time are acquired and analyzed, the machining process and the workpiece quality are compared between using the grid cathode and the unitary cathode. Moreover, the machining errors on the workpiece surface are measured and analyzed, and the error reasons are traced and discussed to obtain the better surface quality of the workpiece. The experiment and analysis results show that the grid cathode can be used to manufacture the workpieces with complex shapes in certain range of the error. The workpiece quality improves with the size of the square cell being reduced, and if the square element is small enough, the workpiece quality is almost equal to the one machined by the unitary cathode. The proposed research realizes a single cathode machining the different workpieces with the different surfaces. | LU Yonghua LIU Kai ZHAO Dongbiao | 2013 | Chinese Journal of Mechanical Engineering2013，26，4： | 1 |
| 8 | Electric discharge phenomenon in dielectric and electrolyte medium显示文摘Electric discharge is a common tool nowadays for machining of materials. It may be through a liquid medium or through air. Any metals, hard alloys, and nonmetals can be machined using the energy of electric discharge. In electric discharge machining (EDM), the discharge occurs between two electrodes through a liquid medium and it is applicable only for electrically con ducting materials and alloys. In electrochemical discharge machining (ECDM), the medium is an aqueous electrolyte and it is of two types. In the first type, the discharge occurs between two electrodes. One of the electrodes is the workpiece, and the other is the tool. In the second type, the discharge occurs between one electrode and an electrolyte. It is used for electrically nonconducting materials and the discharge energy is utilized maintaining the nonconducting workpiece in proximity of the discharge. All these electrical discharges are transient phenomena and do not result in a stable discharge in the form of arc. The output parameters depend on the discharge energy that requires precise control to maintain the accuracy of the machining. For micromachining, the control of the discharge is paramount both in terms of energy and pattern. Using various shaped tools, machining media with additives, different types of applied potentials, and supporting mechanical motions are some of the attempts made to improve the machining output. Optimization of these parameters for machining particular materials (or alloys) is a popular field of research. The present work is directed toward the investigation of discharge initiation and development by analyzing the cell current and discharge voltage relationship for both EDM and ECDM. The rectangular direct current (DC) pulse with different frequencies and the duty factor (on-off time ratio) are used for investigation. Observations on the voltage-current relationship are made for the external potential prior to discharge at discharge and above the discharge potential. Though the external poten tial above the discharge voltage is useful for machining, these observations elucidate the mechanism regarding the initiation of the electric discharge under different condi tions. The manner of discharge development in dielectrics and electrolytes is observed to be different. This understanding will aid in deciding the design of the discharge circuit including the external potential and its pattern for certain desired outputs in machining. | Mukesh Kumar Sindhu Debasish Nandi Indrajit Basak | 2018 | Advances in Manufacturing2018，6，4： | 0 |
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