Scholarlink

<p>The integral shrouded blisk, a high-speed rotor known for its performance and reliability, is extensively used in aerospace applications. Electrical discharge machining (EDM) with multi-axis is a feasible method for processing these components. However, conventional flush struggles with evacuating EDM by-products due to the curved flow channels and small discharge gaps, leading to low machining efficiency. This paper introduces a novel optimized flush with floating feed and suction auxiliary method in EDM of integral shrouded blisks. The optimized flushing device features an internal flow channel in the electrode fixture for effective upper-side flushing. The floating feed method, with small amplitude electrode movements, increases the upper and lower gaps to enhance Liquid entry. A suction tube beneath the electrode evacuates fluid from the lower side gap. Fluid and particle tracking simulations show that increasing the side gap to over 0.3&#xa0;mm enhances the inter-electrode flow velocity by 4–5 times with optimized flush. When combined with optimized flush and a suction pressure of -40&#xa0;kPa at a 0.5&#xa0;mm side gap, the debris concentration in the machining area is reduced from 31.5 to 7%, compared to conventional flush. Experimental results on arc-shaped channels indicate that floating feed with small intervals is effective, with a floating range of 0.2&#xa0;mm proving to be optimal. Higher suction pressures further enhance processing stability and efficiency. Under optimal parameters, the processing efficiency improves by 89.5% in blisk flow channel machining. Therefore, the optimized flush combined with floating feed and suction auxiliary proves highly effective for EDM of integral shrouded blisks.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

A novel optimized flush combined with floating feed and suction auxiliary method in EDM of integral shrouded blisks

  • 期刊论文

  • 发表日期：

    2025年9月20日

查看全文
  • Hongfei Wei,
  • Jing Zhou,
  • Long Cheng,
  • Bowen Shen,
  • Xiaoming Kang

摘要

The integral shrouded blisk, a high-speed rotor known for its performance and reliability, is extensively used in aerospace applications. Electrical discharge machining (EDM) with multi-axis is a feasible method for processing these components. However, conventional flush struggles with evacuating EDM by-products due to the curved flow channels and small discharge gaps, leading to low machining efficiency. This paper introduces a novel optimized flush with floating feed and suction auxiliary method in EDM of integral shrouded blisks. The optimized flushing device features an internal flow channel in the electrode fixture for effective upper-side flushing. The floating feed method, with small amplitude electrode movements, increases the upper and lower gaps to enhance Liquid entry. A suction tube beneath the electrode evacuates fluid from the lower side gap. Fluid and particle tracking simulations show that increasing the side gap to over 0.3 mm enhances the inter-electrode flow velocity by 4–5 times with optimized flush. When combined with optimized flush and a suction pressure of -40 kPa at a 0.5 mm side gap, the debris concentration in the machining area is reduced from 31.5 to 7%, compared to conventional flush. Experimental results on arc-shaped channels indicate that floating feed with small intervals is effective, with a floating range of 0.2 mm proving to be optimal. Higher suction pressures further enhance processing stability and efficiency. Under optimal parameters, the processing efficiency improves by 89.5% in blisk flow channel machining. Therefore, the optimized flush combined with floating feed and suction auxiliary proves highly effective for EDM of integral shrouded blisks.