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Electrochemical machining with a variant cathode for aero-engine stator vanes
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Electrochemical machining with a variant cathode for aero-engine stator vanes
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Journal Article
Electrochemical machining with a variant cathode for aero-engine stator vanes
2025
Overview
Stator vanes with dual-platform (inner and outer platform) structures are essential components of aero engines. Electrochemical machining (ECM) is a highly efficient, low-cost, and high-quality method of machining stator vanes. During ECM, the inner walls of the platforms (IWPs) of the stator vane are easily affected by stray currents, making it difficult to control the machining accuracy. In order to improve the IWP machining quality, an ECM method based on a variant cathode is proposed in this work. When ECM of stator vanes is performed using this method, the three parts of the variant cathode feed synchronously to the vane surface and IWPs respectively. A cathode cooperative motion device is designed for this machining method. The distribution of the current density and flow velocity in the machining gap is obtained through the simulation. The uniformity of current density in the machining area of the IWP is improved by 67.1% and increases the flow velocity of the electrolyte by 9% over those provided by the traditional method. Furthermore, the proposed method enhances the IWP concentrated dissolution capability and reduces the impact of stray currents, resulting in a 41.8% reduction in the taper angle of the IWPs. Experiments are carried out, and the results show that compared with the traditional method, the IWP profile accuracy is improved by 54.4%, and the surface quality is improved by 49.1%. The results are close to those obtained from simulations and theoretical analysis, which verifies the effectiveness of the proposed method.
Publisher
Springer London,Springer Nature B.V
Subject
