Continuous trajectory electrolytic machining method for online deformation of sheet electrodes, electrodes, and applications

Abstract

This invention relates to a continuous trajectory electrolytic machining method for online deformation of a sheet electrode. In this electrolytic machining method, a sheet electrode (1) is manufactured from a material with excellent conductivity and elasticity, and the sheet electrode (1) is divided into multiple regions (1-A, 1-B, 1-C, 1-D, 1-E) based on various machining surfaces. Local insulation treatment is performed on each of the different regions, and during machining, the sheet electrode switches between different machining regions based on the characteristics of the curvature changes of different machining surfaces of the workpiece, receives a load to generate online deformation, and sequentially completes machining of different machining surfaces according to a set trajectory, thereby realizing continuous trajectory electrolytic machining of online deformation of the sheet electrode. This invention also relates to a sheet electrode used in the continuous trajectory electrolytic machining method and a machining method for machining an integrated blisk blade row channel using the sheet electrode. The continuous trajectory electrolytic machining method for online deformation of a sheet electrode realizes continuous machining of multiple complex machining surfaces via a single sheet electrode, improving machining efficiency and making it applicable to machining complex components such as integrated blisks.

Claims

1. A continuous trajectory electrolytic machining method for online deformation of a sheet electrode, A process for manufacturing a sheet electrode with a large aspect ratio using a material having excellent conductivity and elasticity, A process of setting a machining trajectory based on the number of machining surfaces and dividing the sheet electrode into multiple electrode regions along its length, A process of performing local insulation treatment on different electrode regions, During processing, the sheet electrode sequentially completes the processing of different mold surfaces according to a set trajectory, and based on the characteristics of the curvature changes of the different mold surfaces, a load is applied to the sheet electrode during the processing process to generate corresponding online deformation. Different electrode regions correspond to different machining surfaces, and each time machining of one surface is completed, the sheet electrode switches electrode regions through the related movement of the machine tool's spindle, and the process moves to the next surface. A continuous trajectory electrolytic machining method for online deformation of a sheet electrode, characterized by including a step of realizing the flow of electrolyte along the mold surface direction of the sheet electrode by using an open flow field and adding an external electrolyte supply device, since the sheet electrode needs to undergo bending deformation and multi-degree-of-freedom movement during the machining process.

2. A continuous trajectory electrolytic machining method for online deformation of a sheet electrode according to claim 1, applicable to the machining of an integrated brisk blade row channel, The process involves constructing an integrated brisk wing row channel using three mold surfaces: the wing dorsum, hub, and wing ventral surface. A process to set the machining trajectory of the sheet electrode to a "U" shaped machining trajectory, A method characterized by dividing a sheet electrode into three electrode regions and including a step corresponding to the continuous machining of three mold surfaces, namely the wing dorsum, hub, and wing tubular region, in order.

3. A sheet electrode used in the continuous trajectory electrolytic machining method for online deformation of a sheet electrode according to claim 2, The sheet electrode (1) is divided into five electrode regions along its length based on the mold surface characteristics of the integrated brisk blade row channel, and these are respectively referred to as region A (1-A), region B (1-B), region C (1-C), region D (1-D), and region E (1-E). Regions A and E are the clamping regions of the sheet electrode (1), and by applying a load to the clamping regions, online deformation is caused in the sheet electrode (1) during the machining process. The clamping regions of the sheet electrode (1) do not participate in the electrolytic machining. The sheet electrode (1) consists of a pre-processed surface, a post-processed surface, a left-processed surface, and a right-processed surface, and an insulating coating layer (1-F) is coated in different areas of each processed surface. The pre-processed surface, left-processed surface, and right-processed surface of the sheet electrode (1) are used for processing the dorsal surface of the integrated brisk blade row channel. The pre-processed surface is coated with an insulating coating layer and does not participate in electrolytic processing. Most of the left-processed surface and right-processed surface are coated with an insulating coating layer, but a portion of the processing surface adjacent to the pre-processed surface is left to participate in electrolytic processing to facilitate material removal. During the processing, the pre-processed surface is sent from the blade tip to the blade root. The C region of the right-hand processed surface of the sheet electrode (1) is used for processing the hub-shaped surface of the integrated brisk blade row channel, while the B and D regions of the right-hand processed surface are coated with an insulating coating layer and are not involved in electrolytic processing. During the processing, the right-hand processed surface is fed along the hub direction. The sheet electrode (1) is characterized in that the post-processed surface, the left processed surface, and the right processed surface (region B) are used for processing the wing-shaped surface of an integrated brisk blade row channel, the post-processed surface (regions C) and (region D) are coated with an insulating coating layer and do not participate in electrolytic processing, and most of the left processed surface and the right processed surface (region B) are coated with an insulating coating layer, but a portion of the processed surface adjacent to the post-processed surface (region B) is left to participate in electrolytic processing to facilitate material removal, and during the processing process, the post-processed surface is sent from the blade root to the blade tip.

4. A processing method for processing an integrated brisk blade row channel using the sheet electrode described in claim 3, First, the sheet electrode (1) is fed from the wingtip to the wing root, and the D region of the pre-processed surface, left-processed surface, and right-processed surface is processed as the processing surface. During the processing, corresponding online deformation is generated based on the characteristics of the curvature change of the dorsal surface, thereby completing the processing of the dorsal surface in step 1. Step 2 involves rotating the sheet electrode (1) clockwise to switch to the right machining surface, feeding it along the hub direction, and machining the C region of the right machining surface as the machining surface, thereby completing the machining of the hub-shaped surface. A machining method characterized by comprising step 3, which involves rotating a sheet electrode (1) clockwise to switch to a post-machining surface, feeding it from the wing root to the wing tip, machining the post-machining surface, the left machining surface, and the right machining surface in region B as the machining surface, and completing the machining of the wing belly surface by generating corresponding online deformation based on the characteristics of the curvature change of the wing belly surface during the machining process.

5. A continuous trajectory electrolytic machining method for online deformation of a sheet electrode according to claim 1, applicable to the machining of a closed, integrated brisk blade row channel, The process involves constructing a closed, integrated blisk wing row channel using four mold surfaces: the wing dorsum, hub, wing ventral, and shroud. A process to set the machining trajectory of the sheet electrode to an "O" shaped machining trajectory, A method characterized by comprising the step of dividing a sheet electrode into four electrode regions and sequentially completing continuous machining of the four mold surfaces, corresponding to the continuous machining of the wing dorsum, hub, wing ventral, and shroud, respectively.

6. A sheet electrode used in the continuous trajectory electrolytic machining method for online deformation of a sheet electrode according to claim 5, The sheet electrode (1) is divided into five electrode regions along its length based on the mold surface characteristics of the integrated brisk blade row channel, and these are respectively referred to as region A (1-A), region B (1-B), region C (1-C), region D (1-D), and region E (1-E). Regions A and E are the clamping regions of the sheet electrode (1), and by applying a load to the clamping regions, online deformation is caused in the sheet electrode (1) during the machining process. The clamping regions of the sheet electrode (1) do not participate in the electrolytic machining. The sheet electrode (1) consists of a pre-processed surface, a post-processed surface, a left-processed surface, and a right-processed surface, and an insulating coating layer (1-F) is coated in different areas of each processed surface. The pre-processed surface, left-processed surface, and right-processed surface of the sheet electrode (1) are used for processing the dorsal surface of the integrated brisk blade row channel. The B and C regions of the pre-processed surface are coated with an insulating coating layer and do not participate in electrolytic processing. Most of the D region of the left-processed surface and right-processed surface are coated with an insulating coating layer, but a portion of the processed surface adjacent to the D region of the pre-processed surface is left to participate in electrolytic processing to facilitate material removal. During the processing, the pre-processed surface is sent from the blade tip to the blade root. The C region of the right-hand processed surface of the sheet electrode (1) is used for processing the hub-shaped surface of the integrated brisk blade row channel, while the B and D regions of the right-hand processed surface are coated with an insulating coating layer and are not involved in electrolytic processing. During the processing, the right-hand processed surface is fed along the hub direction. The B regions of the post-processed surface, left-processed surface, and right-processed surface of the sheet electrode (1) are used for processing the wing-shaped surface of the integrated brisk blade row channel. The C and D regions of the post-processed surface are coated with an insulating coating layer and do not participate in electrolytic processing. Most of the B regions of the left-processed surface and right-processed surface are coated with an insulating coating layer, but a portion of the processed surface adjacent to the B region of the post-processed surface is left to participate in electrolytic processing to facilitate material removal. During the processing, the post-processed surface is sent from the blade root to the blade tip. A sheet electrode characterized in that the C region of the left processed surface of the sheet electrode is used for processing the shroud-type surface of a closed, integrated brisk blade row channel, and the B and D regions of the left processed surface are coated with an insulating coating layer and do not participate in electrolytic processing, and during the processing process, the left processed surface is fed along the shroud direction.

7. A processing method for processing an integrated brisk blade row channel using the sheet electrode described in claim 6, First, the sheet electrode (1) is fed from the wingtip to the wing root, and the D region of the pre-processed surface, left-processed surface, and right-processed surface is processed as the processing surface. During the processing, corresponding online deformation is generated based on the characteristics of the curvature change of the dorsal surface, thereby completing the processing of the dorsal surface in step 1. Step 2 involves rotating the sheet electrode (1) clockwise to switch to the right machining surface, feeding it along the hub direction, and machining the C region of the right machining surface as the machining surface, thereby completing the machining of the hub-shaped surface. Step 3 involves rotating the sheet electrode (1) clockwise to switch to the post-processing surface, feeding it from the wing root to the wing tip, processing the post-processing surface, the left processing surface, and the right processing surface in region B as the processing surface, and completing the processing of the wing belly surface by generating corresponding online deformation based on the characteristics of the curvature change of the wing belly surface during the processing process. A machining method characterized by including step 4, which involves rotating the sheet electrode (1) counterclockwise to switch to the left machining surface, feeding it along the shroud direction, and machining the C region of the left machining surface as the machining surface to complete the machining of the shroud-shaped surface.

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