<p>Online deformation electrochemical cutting with flexible electrodes (FECC) is a new electrochemical machining (ECM) method. It achieves the machining of complex shapes such as blisk channels by using the action of a load to produce online deformations of a flexible electrode. Since the blisk channel consists of multiple profiles, such as the convex, the hub, the concave, etc., it is not possible to perform continuous machining of multiple profiles using only a single-direction feed of the tool electrode. The addition of a shroud around the blade further increases the difficulty of machining the channel. Therefore, this paper carried out a study on continuous trajectory machining FECC to achieve continuous machining of multiple complex profiles with a single flexible electrode. Herein, the machining principle of continuous trajectory machining of flexible electrodes was introduced in detail, and “U”- and “O”-shaped machining trajectories were designed for open and closed components. In addition, the structural parameters of the flexible electrodes were designed and optimised, and the mechanical, flow field, fluid-structure interaction, and electric field simulations were carried out to obtain the flexible electrodes with optimal overall performance. The processing feasibility of the optimised flexible electrodes was verified by conducting deformation experiments on the flexible electrodes. Finally, the feasibility of continuous trajectory machining of flexible electrodes was verified by successfully machining typical components through experiments. Accordingly, this study offers a new way to machine complex components efficiently.</p>

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Continuous trajectory machining research on online deformation electrochemical cutting with flexible electrodes

  • Lin Liu,
  • Zhengyang Xu,
  • Yunlong Teng

摘要

Online deformation electrochemical cutting with flexible electrodes (FECC) is a new electrochemical machining (ECM) method. It achieves the machining of complex shapes such as blisk channels by using the action of a load to produce online deformations of a flexible electrode. Since the blisk channel consists of multiple profiles, such as the convex, the hub, the concave, etc., it is not possible to perform continuous machining of multiple profiles using only a single-direction feed of the tool electrode. The addition of a shroud around the blade further increases the difficulty of machining the channel. Therefore, this paper carried out a study on continuous trajectory machining FECC to achieve continuous machining of multiple complex profiles with a single flexible electrode. Herein, the machining principle of continuous trajectory machining of flexible electrodes was introduced in detail, and “U”- and “O”-shaped machining trajectories were designed for open and closed components. In addition, the structural parameters of the flexible electrodes were designed and optimised, and the mechanical, flow field, fluid-structure interaction, and electric field simulations were carried out to obtain the flexible electrodes with optimal overall performance. The processing feasibility of the optimised flexible electrodes was verified by conducting deformation experiments on the flexible electrodes. Finally, the feasibility of continuous trajectory machining of flexible electrodes was verified by successfully machining typical components through experiments. Accordingly, this study offers a new way to machine complex components efficiently.