物理场调控的整体构件旋转套料电解加工基础研究

Integral components such as blisks and diffusers are the key components of aero engine. Electrochemical trepanning has its own unique advantages and it is very suitable for manufacturing these components. This project proposes an innovative electrochemical trepanning method by adjusting the physical fields in view of the control difficulties in accuracy, surface quality and machining stability at present. And the following work will be carried out in this project. 1 A new machining method is proposed in which the electric field is adjusted in real time. The relationship between the material removal quantity on the machined surface and the stay voltage will be investigated, then the machining voltage will be adjusted nonlinearly to decrease the machining taper and to realize the uniform thickness of the blade. 2 The relationship between the feeding spiral trajectory and stray dissolution will be investigated. Then the dissolution regulation will be obtained under the adjusting electric field to realize the thickness control of the complex blade. 3 A new electric shielding method is proposed by using the insulating balls surrounding the machined blade. The stray current will be blocked and second machining effects on the blade will decrease obviously. Then the surface quality will be improved. 4 A dynamic lateral flow mode is proposed to supply the electrolyte around the entire blade evenly. This flow mode can weaken the change of flow field and enhance the machining stability. 5 A cathode design method for electrochemical trepanning is proposed based on the equal dissolution on the blade profile. The gap distribution will be analyzed in unequilibrium state, and the design accuracy of the cathode will be enhanced. Experimental investigation will be carried out and the parameters will be optimized to realize the fabrication of integral components such as blisk and diffuse. Original achievements and a wide range of industrial applications will be obtained by this project.

扩压器、整体叶盘等整体构件是航空发动机中的关重件，套料电解加工非常适合难加工材料整体构件的加工。针对套料电解加工存在加工锥度、表面质量和稳定性难以控制等问题，提出物理场调控的整体构件旋转套料电解加工方法。1提出电场实时可控的加工模式，阐明杂散电压与二次腐蚀量的理论关系，通过电场在线调控实现等截面叶片无锥度加工；2研究旋转轨迹与侧向腐蚀协同控制策略，分析变电场下材料侧向溶解规律，实现扭曲叶片厚度可控加工；3提出绝缘粒子屏蔽的套料电解加工方法，控制间隙内杂散电场，提高工件表面完整性；4提出流域密封可控的侧向流动方式，控制间隙内流场均匀性，提高加工稳定性；5提出扭曲型面侧向等速腐蚀阴极设计方法，研究非平衡态下侧面间隙分布规律，提高阴极设计精度。开展扩压器、整体叶盘等旋转套料电解加工应用试验，实现其精密稳定加工。课题研究将获得具有自主知识产权的原创性成果，具有重要的科学理论意义和工程应用价值。

整体叶盘、扩压器等整体构件是航空发动机中的关重件，套料电解加工非常适合难加工材料整体构件的加工。针对套料电解加工中存在加工精度、表面质量和稳定性难以控制等问题，提出物理场调控的整体构件旋转套料电解加工方法。建立了套料电解加工材料溶解模型，阐明了套料电解加工侧面间隙演变规律；提出了变电压电场调控的套料加工方法，建立了电压调控优化数学模型，改善了加工试件锥度；提出了阴极旋转偏移进给套料电解加工模式，优化获得了阴极进给轨迹，提高了整体叶盘叶栅通道加工精度；提出了侧向等速溶解工具阴极设计方法，求解出复杂扭曲型面不同曲率半径下的阴极轮廓，提高了阴极设计精度；设计了复杂型面全轮廓均匀供液、前后缘供液的流场形式，明晰了流场特性参数分布规律，提高了极间间隙内流场均匀性；提出了若干杂散电场屏蔽套料电解加工创新方法，采用绝缘粒子屏蔽、气体辅助绝缘、辅助阳极等方式，改善了加工试件表面质量；开展了整体构件套料电解加工应用研究，研制出大型运输机辅助动力装置大小叶片扩压器试件、第四代涡扇发动机整体叶盘套料加工扇段试件、长征五号运载火箭叶栅试件、新一代弹用发动机向心叶盘试件，显著提高加工精度、效率和表面质量，降低了制造成本。项目发表和录用学术论文14篇，其中SCI收录9篇；申请发明专利17项，其中已授权9项；项目负责人获中国航空学会青年科技奖，入选2019教育部长江学者奖励计划青年学者人才计划。