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电解加工(ECM)是航空发动机整体叶盘制造的主要技术之一,其电解液流场稳定性是影响电解加工精度和表面质量的核心因素。本文在分析原有的二维流场基础上,针对流体在不同流道截面下的流场状态,提出了一种三维复合电解液流场模式,即三股电解液分别从毛坯进气边、叶盆叶根、叶背叶根流入,由排气边交汇流出。采用有限元法对三维复合流场及两类二维流场开展仿真分析,分析结果表明三维复合流场改善了流道突变区域流场状态,有效抑制了二维流场的流场缺陷,有助于提高流场稳定性。对加工区液体流态进行了判断,其结果显示三维复合流场可以满足电解加工要求。开展了3种流场模式的加工速度比较实验,三维复合流场达到的进给速度最高,较二维流场可显著提升加工效率。采用三维复合流场开展了多叶片扇段加工,获得了较好的重复精度与表面质量。
Electrolytic processing (ECM) is one of the major technologies in the manufacture of aero-engine integral leaf disc. The stability of electrolyte flow field is a key factor affecting the machining accuracy and surface quality of the electrolyzer. In this paper, based on the analysis of the original two-dimensional flow field, a three-dimensional composite electrolyte flow field model is proposed for the fluid flow field under different cross-sections. That is, Roots of potted plants and leaves are dorsal rooted and flowed out of the exhaust side. The finite element method is used to simulate the three-dimensional composite flow field and two types of two-dimensional flow field. The analysis results show that the three-dimensional composite flow field can improve the flow field state in the abrupt region of the flow channel and effectively suppress the flow field defects in the two-dimensional flow field. Help to improve the stability of the flow field. The liquid flow field in the processing area was judged, the results show that the three-dimensional composite flow field can meet the requirements of electrolytic processing. The comparison of the processing speed of three kinds of flow field modes was carried out. The three-dimensional composite flow field reached the highest feed rate, which could significantly improve the processing efficiency compared with the two-dimensional flow field. The multi-blade segment processing was carried out by using three-dimensional composite flow field, and good repeatability and surface quality were obtained.