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针对自由曲面整体叶轮提出了一种适用于自由曲面叶片型面精加工的电解工艺(ECM)方法,采用分步法对整体叶轮的叶间通道进行加工,再采用成形阴极对叶片进行精加工,使其满足叶片加工要求。为了实现叶片的精加工,设计了叶片电解精加工实验装置,设计中利用运动仿真软件对成形阴极结构进行了改进,并运用流场模拟软件对阴极流道进行模拟分析,使阴极形状和极间的电解液流速满足加工要求。在加工实验过程中,对阴极的运动路径进行了分析与优化,通过优化减少了进给方向对叶片加工间隙分布不均的影响,并采用高频脉冲电源加工减小加工间隙,提高叶片加工精度。实验结果表明,该工艺方案可行,加工的整体叶轮自由曲面叶片精度得到了显著提高。
Aiming at the integral impeller of the freeform surface, an ECM method for finishing the free-form blade surface is proposed. The step-by-step method is used to process the inter-blade passage of the integral impeller, and the formed cathode is used to finish the blade. Make it meet the blade processing requirements. In order to achieve the blade finishing, the design of the leaf electrolytic finishing experimental apparatus, the use of motion simulation software in the design of the cathode structure was improved, and the use of flow simulation software to simulate the cathode flow channel, the cathode shape and the inter- The electrolyte flow rate to meet the processing requirements. In the course of machining experiments, the movement path of the cathode was analyzed and optimized. The influence of feed direction on the uneven distribution of blade clearance was reduced by optimization. The processing gap was reduced by high-frequency pulse power machining to improve the processing precision . The experimental results show that the process scheme is feasible and the precision of the machined free blade of the integral impeller has been significantly improved.