Casing parts are regarded as key components of aero-engines.Most casing parts are attached to convex structures of different shapes,whose heights range from hundreds of microns to tens of millimeters.Using profiling blocky electrodes for electrochemical machining(ECM)of casing parts is a commonly adopted method,especially when highly convex structures.However,with an increase in the convex structure height,the flow fields of the machin-ing areas become more complex,and short circuits may occur at anytime.In this study,a method to improve the flow field characteristics within a machining area by adjusting the backwater pressure is proposed and validated through simulation and experiment analyses.The simulation results demonstrated that the back-pressure method can significantly improve the uniformity of the flow field around the convex structure compared with the extraction and open outlet modes.Subsequently,the back-pressure value was optimized at 0.5 MPa according to the simulation results.The experimental results showed that using the optimized back-pressure parameters,the cathode feed-rate increased from 0.6 to 0.7 mm/min,and a 16.1 mm tall convex structure was successfully machined.This indicates that the back-pressure method is suitable and effective for electrochemical machining of highly convex structures with blocky electrodes.In this study,we propose a method to improve the electrochemical machining stability of a convex structure on a casing surface using backwater pressure,which has achieved remarkable results.

College of Mechanical Engineering,Yangzhou University,Yangzhou 225000,China

[1]Zhenghui Ge;Wangwang Chen;Yongwei Zhu-.Simulation and Experimental Study on Improving Electrochemical Machining Stability of Highly Convex Structures on Casing Surfaces Using Backwater Pressure)[J].中国机械工程学报,2022(04):334-340

Backwater,millimeters,machin,anytime

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