研究目的
Investigating the influence of flow velocity and flow velocity distribution on the machining accuracy and efficiency of electrochemical machining (ECM) for aero-engine turbine blade cooling holes, specifically comparing mixed gas and non-mixed gas methods.
研究成果
The simulation results show that mixed gas ECM significantly increases flow velocity, improves electrolyte updating, reduces vortex zones, and enhances flow field uniformity, leading to potential improvements in machining accuracy and efficiency for cooling holes.
研究不足
The study is limited to specific materials (Inconel718) and electrolyte (NaNO3), and the simulations are based on 2D models which may not fully capture 3D flow complexities. Experimental repetitions were only 5 times, potentially affecting statistical robustness.
1：Experimental Design and Method Selection:
The study compares two ECM methods: mixed gas added to NaNO3 electrolyte and non-mixed gas. Experiments were conducted on a developed ECM setup using tube electrodes with forward-flow electrolyte.
2：Sample Selection and Data Sources:
Inconel718 nickel-based super-alloy samples of dimension 20×50×
3：5mm were used, clamped at 45°. Brass tube electrodes with 8mm outer diameter and 3mm inner diameter were employed. List of Experimental Equipment and Materials:
ECM setup (developed in-house), tube electrodes (brass), electrolyte (7% NaNO3 solution), gas for mixing, and fluid dynamics software FLUENT for simulation.
4：Experimental Procedures and Operational Workflow:
Experiments were carried out 5 times with averaged results. Process parameters included electrolyte flow rate of 10mL/min, pressure of
5：40 MPa, applied voltage of 6V, and cathode feed rate of 48 mm/min. CAD models were constructed based on experimental data, and numerical simulations were performed using FLUENT. Data Analysis Methods:
Flow velocity and vortex zone distributions were analyzed through CFD simulations, with qualitative and quantitative comparisons between mixed and non-mixed gas conditions.
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