Optimization Method of Insulating Sleeves in Electrochemical Trepanning for Disks

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

Abstract

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

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

CLC Number:

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.

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.

Figures/Tables 20

Fig.1 Electrochemical trepanning tool cathode model

Fig.2 Schematic diagram of tool cathode deformation

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

Fig.4 Flowchart of the insulating sleeve design process

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

Fig.5 Fluid-structure interaction simulation model

Fig.6 Fluid model

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

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

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

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

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

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

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

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

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

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

Fig.13 Insulating sleeves without reinforcement ribs and machined blade

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

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

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

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