复杂曲面构件电解加工动态成型的阴极修正研究

The quality of complex surface components determines the engine performance. Blisk as one of the complex surface components is the key components of aero engine. Electrochemical machining (ECM) has its own unique advantages, such as no cathode loss, high efficiency, so it has become the main manufacturing method for these engine components. In the ECM process of complex surface components, cathode design and modification is the core technology to improve precision. And the following work will be carried out in this project. 1) A new cathode modification method, which is based on the dynamic shaping process in ECM, is proposed in order to enhance current low accuracy of cathode design, low efficiency and generality of the cathode modification. 2) A dynamic shaping law model is established by studying the characteristics of electric field, flow field, and electrochemical field in machining channel. Then the distribution of the electric field and flow field will be optimized according to this model. 3) The cathode profile will be modified by using fuzzy control algorithm on the basis of the dynamic shaping law analysis. Then the cathode's design accuracy will be improved greatly and a foundation for high efficiency and precision in ECM process will be laid. 4) Experimental investigation on complex surface components will be conducted to improve the model accuracy and generality by optimizing the parameters. Groundbreaking achievements and a wide range of industrial applications will be obtained by this project.

整体叶盘等复杂曲面构件是航空发动机中关键部件，其质量好坏直接决定了航空发动机性能。电解加工具有无工具损耗、加工效率高等突出优势，已成为整体叶盘等复杂曲面构件的主流制造技术。在复杂曲面构件电解加工技术中，阴极精确设计与修正是提高加工精度的核心所在，课题针对阴极设计和修正问题将开展以下工作：1）针对目前阴极设计精度不高、阴极修正效率低、通用性不强等问题，提出基于电解加工动态成型过程的阴极修正方法。2）研究动态成型过程中电场、流场、电化学场的特性，建立多场耦合条件下的成型规律模型，优化间隙内的电场、流场分布。3）根据动态成型规律分析，采用模糊控制算法逆向修正阴极型面，提高阴极设计精度，为高效、精密电解加工奠定基础。4）开展复杂曲面构件电解加工试验研究，优化模型中各项参数，提高模型正确性和通用性。本课题研究将获得具有自主知识产权的原创性成果，具有重要和广泛的工业应用价值。

整体叶盘/叶片是航空发动机中最为重要的零部件，其型面扭曲、结构复杂、材料难加工、精度要求高，对制造技术提出了很高要求。电解加工技术是加工整体叶盘/叶片的主要制造方法。项目针对整体叶盘/叶片等复杂曲面零部件的电解加工技术开展研究，提出一种基于电解加工动态成型预测的阴极修正方法，建立了加工间隙中电场、流场数学模型，计算得到了气泡、热量、压力、流速沿程分布规律，分析了复杂曲面电解加工动态成型规律，根据预测型面修正阴极型面，提高了阴极设计精度。提出了动态辅助补液、三维复合流场的流动方式，提高了整体叶盘电解加工稳定性和加工效率。针对整体叶盘典型零部件，研制了斜置式工装夹具，采用优化设计阴极开展了电解加工工艺试验，研制出整体叶盘试验件，提高了试件加工精度。项目涉及的设计方法可应用于各类复杂型面零部件电解加工的阴极设计，提高设计精度，具有重要科学意义和广泛的工业应用价值。项目共发表录用核心期刊论文13篇，其中SCI论文7篇。申请发明专利6项，其中已授权2项。培养研究生8名。项目负责人的博士学位论文获得全国优秀博士学位论文提名，项目负责人指导的本科毕设获江苏省普通高等学校本专科优秀毕业设计（论文）二等奖。