整体叶盘套形电解加工绝缘套优化方法研究

doi:10.3969/j.issn.1004-132X.2026.02.015

摘要/Abstract

摘要：

减小套形电解加工过程中的绝缘套变形是提高套形电解加工稳定性和精度的重要措施。提出了一种绝缘套优化方法。以弦长20 mm、叶片高度23 mm、叶片厚度0.54 mm的薄壁叶片为例，建立了不同绝缘套结构的工具阴极模型，开展了流固耦合仿真研究，优化了绝缘套加强筋结构参数。相比于无加强筋结构的绝缘套，优化后绝缘套最大变形量从0.261 mm减至0.020 mm，同时加工区域流速分布较为均匀。开展了绝缘套加强筋宽度为0、1、2、4.5 mm的薄壁叶片套形电解加工试验，加工出薄壁叶片，相比于无加强筋结构的绝缘套，加强筋宽度为4.5 mm时，加工叶片的表面粗糙度Ra从1.81 µm减至1.05 µm，验证了所提方法可有效减小绝缘套变形量，提高套形电解加工稳定性。

关键词: 套形电解加工, 薄壁叶片, 绝缘套, 流固耦合仿真, 正交试验

Abstract:

Reducing the deformations of the insulating sleeves during the ECT processes was an important method to improve the stability and accuracy of ECT. This paper proposed an optimization method for the insulating sleeves. With a thin-walled blade of chord length 20 mm， blade height 23 mm， and blade thickness 0.54 mm as an example， tool cathode models with different insulating sleeve structures were established， FSI simulations were conducted， and the structural parameters of the insulating sleeve reinforcement ribs were optimized. Compared with the insulating sleeves without reinforcement ribs， the maximum deformation of the optimized insulating sleeves is reduced from 0.261 mm to 0.020 mm， and the velocity distribution in the machining area becomes more uniform. ECT experiments were carried out on thin-walled blades with insulating sleeve reinforcement widths of 0 mm， 1 mm， 2 mm， and 4.5 mm respectively. The results show that， compared with the insulating sleeve without reinforcement ribs， the value of surface roughness of the machined blades with a reinforcement width of 4.5 mm is reduced from 1.81 µm to 1.05 µm. The method was verified to be effective in reducing the deformations of the insulating sleeve and improving the stability of ECT.

Key words: electrochemical trepanning（ECT）, thin-walled blade, insulating sleeve, fluid-structure interaction （FSI） simulation, orthogonal experiment

中图分类号:

王云淼, 朱栋, 焦尔豪, 王欢, 张超, 王若龙. 整体叶盘套形电解加工绝缘套优化方法研究[J]. 中国机械工程, 2026, 37(2): 398-405.

WANG Yunmiao, ZHU Dong, JIAO Erhao, WANG Huan, ZHANG Chao, WANG Ruolong. Optimization Method of Insulating Sleeves in Electrochemical Trepanning for Disks[J]. China Mechanical Engineering, 2026, 37(2): 398-405.

导出引用管理器 EndNote|Ris|BibTeX

链接本文: https://www.cmemo.org.cn/CN/10.3969/j.issn.1004-132X.2026.02.015

https://www.cmemo.org.cn/CN/Y2026/V37/I2/398

图/表 20

图1 套形电解加工工具阴极模型

Fig.1 Electrochemical trepanning tool cathode model

图2 工具阴极变形示意图

Fig.2 Schematic diagram of tool cathode deformation

图3 加强筋对绝缘套变形的影响示意图

Fig.3 Schematic diagram of the effect of reinforcement ribs on the deformation of the insulating sleeve

图4 绝缘套设计流程图

Fig.4 Flowchart of the insulating sleeve design process

表1 正交因素及水平

Tab.1 Orthogonal factors and levels

因素	水平1	水平2	水平3	水平4	水平5
加强筋个数	0	1	2	3	4
加强筋宽度/mm	0.50	1.25	2.00	2.75	3.50
加强筋位置/mm	0	5	10	15	20

图5 流固耦合仿真模型

Fig.5 Fluid-structure interaction simulation model

图6 流体模型

Fig.6 Fluid model

图7 正交试验绝缘套最大、最小变形云图

Fig.7 Contour maps of maximum and minimum deformation of the insulating sleeve of the orthogonal experiment

图8 正交试验云图截面内的流速云图

Fig.8 Velocity contour maps within the cross-section of the orthogonal experiment

表2 三因素五水平正交表及仿真结果汇总

Tab.2 Three-factor， five-level orthogonal table and summary of simulation results

编号	加强筋个数	加强筋宽度/mm	加强筋位置/mm	绝缘套变形量/mm	低流速点占比/%	综合评价指标
1	0	0.50	0	0.261	2.69	6.97
2	0	1.25	10	0.261	2.69	6.96
3	0	2.00	20	0.119	3.10	3.49
4	0	2.75	5	0.261	2.69	7.24
5	0	3.50	15	0.261	2.69	5.45
6	1	0.50	20	0.301	2.49	6.98
7	1	1.25	5	0.246	2.18	6.51
8	1	2.00	15	0.260	2.76	6.61
9	1	2.75	0	0.177	3.03	6.67
10	1	3.50	10	0.240	2.99	2.85
11	2	0.50	15	0.280	2.68	6.96
12	2	1.25	0	0.207	2.32	7.95
13	2	2.00	10	0.254	2.88	6.82
14	2	2.75	20	0.249	2.27	4.57
15	2	3.50	5	0.119	3.10	7.11
16	3	0.50	10	0.248	2.85	6.99
17	3	1.25	20	0.271	2.75	6.49
18	3	2.00	5	0.230	3.65	5.55
19	3	2.75	15	0.251	3.75	6.90
20	3	3.50	0	0.122	9.10	6.58
21	4	0.50	5	0.247	2.46	6.96
22	4	1.25	15	0.264	3.07	4.93
23	4	2.00	0	0.081	4.90	7.44
24	4	2.75	10	0.179	5.76	6.36
25	4	3.50	20	0.231	6.64	6.88

表3 综合评价指标极差分析

Tab.3 Range analysis of comprehensive evaluation indicator

	加强筋个数	加强筋宽度/mm	加强筋位置/mm
k₁	6.97	7.12	4.97
k₂	6.57	6.67	5.98
k₃	5.98	5.99	6.48
k₄	6.35	6.17	7.08
k₅	5.77	5.68	7.13
R	1.20	1.44	2.16

图9 加强筋数量对绝缘套最大变形量的影响

Fig.9 Effect of the number of reinforcement ribs on the maximum deformation of the insulating sleeve

图10 绝缘套最大变形量和加强筋宽度的关系

Fig.10 Relationship between the maximum deformation of the insulating sleeve and the width of the reinforcement ribs

图11 薄壁叶片套形电解加工装置示意图

Fig.11 Schematic diagram of the electrochemical trepanning device for thin-walled blades

表4 薄壁叶片套形电解加工参数

Tab.4 Electrochemical trepanning parameters for thin-walled blades

电解液	20%NaNO₃水溶液
电解液温度/°C	30
进给速度/（mm·min $- 1$ ）	2.1
初始加工间隙/mm	0.5
电解液入口压力/MPa	1
电解液出口压力/MPa	0
加工电压/V	20

表4 薄壁叶片套形电解加工参数

Tab.4 Electrochemical trepanning parameters for thin-walled blades

电解液	20%NaNO₃水溶液
电解液温度/°C	30
进给速度/（mm·min $- 1$ ）	2.1
初始加工间隙/mm	0.5
电解液入口压力/MPa	1
电解液出口压力/MPa	0
加工电压/V	20

图12 加强筋宽度0、2、4.5 mm时的加工电流

Fig.12 Machining current for reinforcement rib widths of 0，2，4.5 mm

图13 无加强筋绝缘套和加工叶片

Fig.13 Insulating sleeves without reinforcement ribs and machined blade

图14 不同加强筋绝缘套加工叶片的轮廓

Fig.14 Contour of the blade machined with different reinforcement rib widths

表5 不同加强筋宽度下加工叶片粗糙度

Tab.5 Surface roughness of blades machined with different reinforcement rib widths

加强筋宽度d/mm	粗糙度Ra/µm
0	1.81
1	1.57
2	1.26
4.5	1.05

图15 不同加强筋宽度下加工叶片粗糙度检测

Fig.15 Surface roughness inspection of blades machined with different reinforcement rib widths

参考文献 19

[1]	KLOCKE F， KLINK A， VESELOVAC D， et al. Turbomachinery Component Manufacture by Application of Electrochemical， Electro-physical and Photonic Processes［J］. CIRP Annals， 2014， 63（2）： 703-726.
[2]	SRINIVAS G， RAGHUNANDANA K， SATISH SHENOY B. Recent Developments in Turbomachinery Component Materials and Manufacturing Challenges for Aero Engine Applications［J］. IOP Conference Series： Materials Science and Engineering， 2018， 314（1）： 012012.
[3]	BEWLAY B P， WEIMER M， KELLY T， et al. The Science， Technology， and Implementation of TiAl Alloys in Commercial Aircraft Engines［J］. MRS Online Proceedings Library， 2013， 1516（1）： 49-58.
[4]	刘嘉.提高整体叶盘型面电解加工精度的若干关键技术研究［D］. 南京：南京航空航天大学， 2014.
	LIU Jia. Research on Key Technologies to Improve the Electrochemical Machining Accuracy of Aero-engine Blisk ［D］. Nanjing： Nanjing University of Aeronautics and Astronautics， 2014.
[5]	朱荻，刘嘉，王登勇，等. 脉动态电解加工［J］. 航空学报， 2022， 43（4）： 1-14.
	ZHU Di， LIU Jia， WANG Dengyong， et al. Pulse Dynamic Electrochemical Machining［J］. Acta Aeronautica et Astronautica Sinica， 2022， 43（4）： 1-14.
[6]	王刚，赵万生. 涡轮制造技术的现状和发展［J］. 航空工程与维修， 2000（4）： 41-43.
	WANG Gang， ZHAO Wansheng. Present Situation and Development of Turbine Manufacturing Technology［J］. Aviation Engineerging & Mainienance， 2000（4）： 41-43.
[7]	姜云龙. 埃马克电化学公司关于整体叶盘精密电解加工工艺综述——面向未来的技术［C］//2014年全国电化学加工技术研讨会. 合肥，2014： 37-43.
	JIANG Yunlong. EMCG ECM GmbH—A PECM Cost-saving Approach to Blisk Manufacturing ［C］//2014 Chinese Electrochemical Processing Technology Symposium. Hefei，2014： 37-43.
[8]	江晨，杨波，吴从焰，等. 电解加工在航空航天领域的应用研究［J］. 机械制造， 2020， 58（2）： 63-66.
	JIANG Chen， YANG Bo， WU Congyan， et al. Study on Application of Electrolytic Machining in Aviation and Aerospace Field［J］. Machinery， 2020， 58（2）： 63-66.
[9]	MINAZETDINOV N M. A Hydrodynamic Interpretation of a Problem in the Theory of the Dimensional Electrochemical Machining of Metals［J］. Journal of Applied Mathematics and Mechanics， 2009， 73（1）： 41-47.
[10]	BHATTACHARYYA B， MALAPATI M， MUNDA J， et al. Influence of Tool Vibration on Machining Performance in Electrochemical Micro-machining of Copper［J］. International Journal of Machine Tools and Manufacture， 2007， 47（2）： 335-342.
[11]	田继安，华玉其，李国宏. 小间隙脉冲电流电解加工工艺试验研究［J］. 电加工， 1985（1）： 2-6.
	TIAN Ji'an， HUA Yuqi， LI Guohong. Experimental Study on Small Gap Pulse Current Electrochemical Machining Process［J］. Electromachining & Mould， 1985（1）： 2-6.
[12]	JIA Jianli， XU Jiang， PANG Y， et al. Research on Pitting Control Technology of Titanium Alloy Cascade Trepanning Electrochemical Machining［J］. The International Journal of Advanced Manufacturing Technology， 2023， 128（5）： 2781-2796.
[13]	TAO Jin， XU Jinkai， REN Wanfei， et al. Research on Multi-physics Field Coupling Dynamic Process in Forward Flow Electrochemical Trepanning Blades［J］. Journal of the Electrochemical Society， 2022， 169（10）： 103501.
[14]	秦天天. 空气绝缘辅助套料电解加工关键技术研究［D］.淮阴：淮阴工学院， 2024.
	QIN Tiantian. Research on Key Technologies of Air Insulation Assisted Nesting Electrochemical Machining［D］. Huaiyin： Huaiyin Institute of Technology， 2024.
[15]	翟士民，张明岐，黄明涛，等. 整体叶盘狭小叶栅通道电解旋转套料加工［J］. 电加工与模具， 2020（6）： 48-51.
	ZHAI Shimin， ZHANG Mingqi， HUANG Mingtao， et al. Electrochemical Rotating Nesting Machining for the Narrow Cascade Channel of Blisk［J］. Electromachining & Mould， 2020（6）： 48-51.
[16]	ZHU Dong， GU Zhouzhi， XUE Tingyu， et al. Simulation and Experimental Investigation on a Dynamic Lateral Flow Mode in Trepanning Electrochemical Machining［J］. Chinese Journal of Aeronautics， 2017， 30（4）： 1624-1630.
[17]	JIAO Erhao， ZHU Dong， ZHANG Chao， et al. Research on the Characteristics of Multiphysics Coupling Fields in the Electrochemical Trepanning of an Inward Facing Blisk［J］. Journal of Manufacturing Processes， 2023， 93： 60-74.
[18]	李正寅，朱栋，张晓博. 扩压器套料电解加工绝缘套结构刚度优化研究［J］. 南京航空航天大学学报， 2022， 54（3）： 378-386.
	LI Zhengyin， ZHU Dong， ZHANG Xiaobo. Study on Structural Stiffness Optimization of Insulating Sleeve for Electrochemical Trepanning of Diffuser［J］. Journal of Nanjing University of Aeronautics & Astronautics， 2022， 54（3）： 378-386.
[19]	LEI Gaopan， ZHU Dong， LI Jiabao. Optimization of Flow Field in Electrochemical Trepanning of Integral Cascades （Ti₆Al₄V）［J］. Chinese Journal of Aeronautics， 2022， 35（10）： 354-364.