A vortex generator double-sided array blade integrated forming electrolytic machining tool and method

Abstract

The present application relates to the technical field of turbine double-sided array blade processing of an aero-engine, and particularly relates to a turbine double-sided array blade integrated forming electrolytic machining tool and method, through the continuous feeding of the left and right tool cathodes to the direction of the part to be processed at the same time, the double-sided array blade is simultaneously machined; the machining tool comprises a cathode clamping block, a tool cathode, a sealing device and a support seat device; a plurality of electrolyte input channels are arranged on the left and right sides of the support seat, the liquid of the electrolyte input channels passes through the flow blocking cavity of the sealing device, the electrolyte is integrated and then flows into the machining area, then flows to the current collection area arranged in the cathode clamping block through the built-in plastic insulation device of the tool cathode, and finally flows out of the electrolyte output channel. Through the double-sided multi-feature integrated forming electrolytic machining technology, the machining efficiency and machining precision can be improved; the electrolyte flow channel adopting the reverse flow type flow field design can effectively improve the uniformity of the flow field.

Description

An electrolytic machining tool and method for integral forming of double-sided array blades of an eddy current generator. Technical Field

[0001] This invention relates to the field of machining technology for double-sided array blades of aero-engine vortex generators, and in particular to an electrolytic machining tool and method for integral forming of double-sided array blades of vortex generators. Background Technology

[0002] New-generation advanced aero-engines often employ integral components where blades and rotors are integrated, such as vortex generators and rectifiers. Compared to traditional assembly structures, this saves a significant number of component assembly steps, simplifying the structure, reducing weight, and greatly improving the engine's thrust-to-weight ratio. However, it also presents new challenges to manufacturing technology. The vortex generator is one of the most important components in the aero-engine combustion chamber. Its rotor has multiple thin-walled blades evenly distributed on both sides, with significant differences in the radius of curvature between the blade head, blade back, and leading and trailing edges. The blade passages are narrow, and the blades on both sides are staggered. The overall rigidity of the part is weak, resulting in a high material removal rate from the forged blank to the final state. The machining process is prone to deformation, posing challenges to manufacturing.

[0003] Currently, there are three feasible machining methods: CNC milling, electrical discharge machining (EDM), and electrolytic machining. For difficult-to-machine materials like nickel-based superalloys, CNC milling uses relatively small cutting parameters. When machining narrow-channel blades, small-diameter tools are used, resulting in even smaller depths of cut, thus leading to longer machining times and higher tool costs. Furthermore, this component is a typical thin-walled part, and thin-walled blades are prone to deformation during machining, and deformation control has always been a challenge in milling processes. CNC EDM suffers from high electrode wear, slow machining speed, and the problems of recast layers and microcracks remaining on the workpiece surface still require overcoming.

[0004] Compared to CNC milling and EDM, electrochemical machining (ECM) technology has unique advantages. Based on the principle of electrochemical anodic dissolution to remove excess material, this process involves no contact between the workpiece anode and the tool cathode during machining. It boasts significant advantages such as zero tool cathode wear, no macroscopic cutting forces, no limitations imposed by the physical and chemical properties of the workpiece material, high machining accuracy, good surface quality, and high machining efficiency, making it an ideal machining process for double-sided array blades of eddy current generators. Nested electrochemical machining is a typical application of ECM technology. This technology can integrally machine the blade base and leading and trailing edges, but it also produces tool marks on the wheel surface. Furthermore, the flow field often adopts a diffusion flow pattern, with significant variations in electrolyte velocity and pressure at the inlet and outlet, leading to poor machining stability and accuracy. Therefore, this study explores a new ECM method and designs corresponding tools based on the characteristics of double-sided array blades of eddy current generators, combining the principles of ECM. This is expected to improve the uniformity of the flow field during ECM machining, thereby enhancing machining stability and accuracy. Summary of the Invention

[0005] The purpose of this invention is to provide an electrolytic machining tool and method for integral forming of double-sided array blades of eddy current generators, so as to solve the technical problems existing in the background art.

[0006] To achieve the above objectives, the technical solution of the present invention is as follows:

[0007] An electrolytic machining tool for integral forming of eddy current generator double-sided array blades includes: an annular support base and a blank to be processed. The annular support base is connected to the positive terminal of the machine tool power supply. The blank to be processed is detachably fixedly connected to a shielding ring built into the annular support base. Several electrolyte input channels are evenly distributed radially on the left and right sides of the annular support base. Two sealing devices are symmetrically arranged on the left and right sides of the annular support base. A first cathode assembly and a second cathode assembly are axially slidably connected to the inner walls of the two sealing devices, respectively. The first cathode assembly and the second cathode assembly move towards or away from each other. Both the first cathode assembly and the second cathode assembly are connected to the negative terminal of the machine tool power supply. The working ends of the first cathode assembly and the second cathode assembly are respectively fitted with the machining planes on the left and right sides of the blank to be processed. The first cathode assembly and the second cathode assembly are respectively provided with a first cathode machining blade and a second cathode machining blade that cooperate with the double-sided array blades of the eddy current generator. The first cathode assembly and the second cathode assembly are also respectively provided with a plurality of electrolyte output channels. The electrolyte enters the gap between the first cathode assembly and the blank to be processed on the opposite side of the first cathode assembly and the second cathode assembly through the plurality of electrolyte input channels on the left and right sides, and flows out through the plurality of electrolyte output channels on the left and right sides through the first cathode machining blade and the second cathode machining blade.

[0008] Furthermore, it also includes a first sealing ring, of which two are provided, and the two first sealing rings are respectively disposed between the annular support and the two sealing devices on the left and right sides.

[0009] Furthermore, the annular support seat is detachably fixed to the machine tool slot, and the left non-machined plane of the blank to be processed is in contact with the right working surface of the built-in shielding ring of the annular support seat.

[0010] Furthermore, the sealing device is an axially hollow frustum shape, and the protrusion of the sealing device extends into the inner cavity of the annular support seat.

[0011] Furthermore, the first cathode assembly includes: a first tool cathode, a first cathode sidewall insulation device, a first cathode center hole insulation device, a cathode clamping block, and a cathode mounting block. The second cathode assembly includes: a second tool cathode, a second cathode sidewall insulation device, a second cathode center hole insulation device, a cathode clamping block, and a cathode mounting block. The inner walls of the two sealing devices are respectively sealed and slidably connected to the first tool cathode and the second tool cathode. The opposing sides of the first tool cathode and the second tool cathode are respectively clearance-fitted with the machining planes on the left and right sides of the workpiece to be processed. The outer ends of the first tool cathode and the second tool cathode are respectively detachably inserted with the first cathode sidewall insulation device and the second cathode sidewall insulation device. The first cathode sidewall insulation device and the second cathode sidewall insulation device are respectively provided with openings on both sides of the eddy current generator. The array blades are matched with a first deep narrow groove and a second deep narrow groove, both of which extend through the left and right sides. The inner ends of the first tool cathode and the second tool cathode facing each other are respectively provided with a first cathode machining edge and a second cathode machining edge corresponding to the first deep narrow groove and the second deep narrow groove. The outer ends of the first tool cathode and the second tool cathode are respectively detachably fixedly connected to two cathode clamping blocks. The two cathode clamping blocks are symmetrically opened on the opposite side of the two cathode clamping blocks in two electrolyte manifolds. The cathode clamping blocks are provided with several electrolyte output channels that communicate with the electrolyte manifolds. The outer ends of the cathode clamping blocks are detachably fixedly connected to cathode mounting blocks. The two cathode mounting blocks are detachably fixedly mounted on two opposing spindles of the machine tool. The two spindles move towards each other or away from each other. Both cathode mounting blocks are connected to the negative terminal of the machine tool power supply.

[0012] Furthermore, the machining planes on the left and right sides of the blank to be processed are respectively provided with a first cathode center hole insulation device and a second cathode center hole insulation device between the center holes of the first tool cathode and the second tool cathode.

[0013] Furthermore, it also includes: a second sealing ring, two of which are symmetrically arranged on the left and right sides, and the two second sealing rings are respectively arranged between the first tool cathode and the sealing device on the left side and between the second tool cathode and the sealing device on the right side.

[0014] Furthermore, the outer ends of the first tool cathode and the second tool cathode are respectively provided with a first embedding groove and a second embedding groove, and the first cathode sidewall insulation device and the second cathode sidewall insulation device are respectively detachably inserted into the first embedding groove and the second embedding groove.

[0015] An electrolytic machining method for integral forming of eddy current generator double-sided array blades, utilizing an electrolytic machining tool for integral forming of eddy current generator double-sided array blades, specifically includes the following steps:

[0016] Step 1: Place the ring support fixing ring into the machine tool slot and axially position it through the two side walls of the machine tool slot. Then fix the two together with screws and connect the ring support to the positive terminal of the power supply.

[0017] Step 2: Place the blank to be processed on the shielding ring inside the annular support base, use the corresponding pin hole for radial positioning, use the working surface of the shielding ring for axial positioning, and fix the blank to be processed to the annular support base with screws.

[0018] Step 3: Place the first cathode sidewall insulation device into the first embedding groove on the first tool cathode and position it; place the second cathode sidewall insulation device into the second embedding groove on the second tool cathode and position it; position the two cathode clamping blocks with the first tool cathode and the second tool cathode respectively, and connect them with screws; embed the first cathode center hole insulation device and the second cathode center hole insulation device into the center hole positions of the first tool cathode and the second tool cathode respectively, and connect them with screws; sleeve the two second sealing rings on the opposite side of the outer wall of the first tool cathode and the second tool cathode respectively; move the inner ends of the first tool cathode and the second tool cathode to the positions that mate with the gaps of the two machining planes on the left and right sides of the blank to be processed; slide the two sealing devices onto the outer wall of the first tool cathode and the second tool cathode respectively.

[0019] Step 4: Insert the two first sealing rings into the side wall grooves on the left and right sides of the annular support seat respectively, and position the two sealing devices to the left and right sides of the annular support seat through the pin holes and fix them with screws.

[0020] Step 5: Secure the two cathode mounting blocks to the two cathode clamping blocks on the left and right sides respectively using screws;

[0021] Step 6: Secure the two cathode mounting blocks to the two opposing spindles of the machine tool using screws, and align them with the machine tool's work platform. Then, connect the negative terminal of the power supply.

[0022] Step 7: Insert the dried liquid inlet pipe into the several electrolyte inlet channels corresponding to the annular support base and the several electrolyte outlet channels corresponding to the two cathode clamping blocks respectively;

[0023] Step 8: Before starting the machine, check whether the power supply, chiller, compressed air, and electrolyte filtration system of the machine tool are normal, and check whether there are any abnormalities on the outside of the machine tool;

[0024] Step 9: After the inspection is completed, test the electrolyte and check the sealing.

[0025] Step 10: Set the eddy current electrolytic machining process parameters: electrolyte is 10% NaNO3, machining voltage is 7V, electrolyte inlet pressure is 0.8MPa, outlet pressure is 0.3MPa, electrolyte temperature is 298K, adopt the machining mode of precise matching between cathode vibration phase and pulse power output, amplitude is 0.3mm, vibration frequency is 10Hz, and conduction angle is 150°;

[0026] Step 11: Simultaneously feed the first tool cathode and the second tool cathode towards the blank to be processed. After completing the one-piece forming of the double-sided blades of the eddy current generator, cut off the power, move the two spindles of the machine tool back to back a certain distance, take out the processed part, and rinse it with clean water.

[0027] Step 12: Measure and record the processed sample using a coordinate measuring machine, analyze the normal error between each point and the theoretical surface, and further correct and optimize multiple parameters through multiple experiments until the processing meets the design requirements.

[0028] Compared with the prior art, the beneficial effects of the present invention are:

[0029] This invention utilizes the principle of electrochemical anodic dissolution to remove excess material. During processing, there is no contact between the workpiece anode and the tool cathode, and no macroscopic cutting force. Therefore, the surface of the processed parts will not generate residual stress or deformation, and there will be no burrs or flash. Furthermore, the tool cathode will not experience any wear during processing; its geometry and dimensions remain essentially unchanged, allowing for long-term use and reducing the manufacturing cycle and cost of the tool cathode. The multi-feature integrated forming electrolytic machining method effectively improves surface quality and machining accuracy. The flow field design of the tool and tool cathode employs a reverse flow pattern, resulting in good flow field uniformity, preventing cavitation, and offering better machining accuracy and stability compared to other flow field forms. The use of plastic insulation devices for sidewall insulation prevents damage or detachment of the insulation devices due to high-speed scouring by the electrolyte, and avoids secondary corrosion of the processed parts. Simultaneous feeding of both tool cathodes towards the workpiece allows for the simultaneous processing of the double-sided array blades, improving processing efficiency. Attached Figure Description

[0030] Figure 1 is a cross-sectional view of an electrolytic machining tool for integral forming of double-sided array blades of a vortex generator according to the present invention;

[0031] Figure 2 is a perspective view of an electrolytic machining tool for integral forming of double-sided array blades of a vortex generator according to the present invention;

[0032] Figure 3 is a structural view of the array blades on the front side of the workpiece after forming according to the present invention;

[0033] Figure 4 is a structural view of the reverse-side array blades after the workpiece of the present invention has been formed;

[0034] Figure 5 is a perspective view of the workpiece after forming according to the present invention;

[0035] Figure 6 is a structural view of the first tool cathode of the present invention;

[0036] Figure 7 is a structural view of the first cathode sidewall insulation device of the present invention;

[0037] Figure 8 is a structural view of the second tool cathode of the present invention;

[0038] Figure 9 is a structural view of the second cathode sidewall insulation device of the present invention.

[0039] The reference numerals in the attached diagram are as follows: 1-ring support, 101-electrolyte input channel, 2-workpiece, 3-sealing device, 4-first sealing ring, 5-first tool cathode, 6-second tool cathode, 7-second sealing ring, 8-first cathode sidewall insulation device, 801-first deep narrow groove, 9-second cathode sidewall insulation device, 901-second deep narrow groove, 10-first cathode center hole insulation device, 11-second cathode center hole insulation device, 12-cathode clamping block, 1201-electrolyte manifold, 1202-electrolyte output channel, 13-cathode mounting block. Detailed Implementation

[0040] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0041] Referring to Figures 1-9, an electrolytic machining tool for integral forming of double-sided array blades of an eddy current generator includes: an annular support base 1 and a blank 2 to be processed. The annular support base 1 is connected to the positive terminal of the machine tool power supply. The blank 2 to be processed is detachably fixedly connected to the built-in shielding ring of the annular support base 1. Several electrolyte input channels 101 are evenly opened radially on the left and right sides of the annular support base 1. Two sealing devices 3 are symmetrically arranged on the left and right sides of the annular support base 1. The inner walls of the two sealing devices 3 are axially slidably connected to a first cathode assembly and a second cathode assembly, respectively. The first cathode assembly and the second cathode assembly move towards or away from each other. Both the first cathode assembly and the second cathode assembly are connected to the negative terminal of the machine tool power supply. The working ends of the first cathode assembly and the second cathode assembly are respectively clearance-fitted with the machining planes on the left and right sides of the blank 2 to be processed. The first cathode assembly and the second cathode assembly are respectively provided with features that correspond to the double-sided array blades of the eddy current generator. The array blades are equipped with a first cathode machining edge and a second cathode machining edge, which are narrow slots corresponding to the double-sided array blades of the eddy current generator. The double-sided array blades of the eddy current generator can be integrally formed by the blade base, blade back and leading and trailing edges through the nested electrolytic machining method. The first cathode assembly and the second cathode assembly are also provided with a number of electrolyte output channels 1202. The electrolyte flows into the gap between the first cathode assembly and the blank 2 to be processed on the opposite side of the first cathode assembly and the second cathode assembly and the blank 2 to be processed through the first cathode machining edge and the second cathode machining edge and the number of electrolyte output channels on the left and right sides. During this process, the blank 2 to be processed undergoes electrochemical dissolution at the anode, and produces flocculent processing products and hydrogen bubbles are formed on the surface of the tool cathode as the electrolyte flows.

[0042] It also includes a first sealing ring 4, of which there are two. The two first sealing rings 4 are respectively disposed between the annular support 1 and the two sealing devices 3 on the left and right sides.

[0043] The annular support 1 has an external fixing ring that is detachably fixed to the machine tool slot. The left non-machined plane of the blank 2 to be processed is in contact with the right working surface of the built-in shielding ring of the annular support 1.

[0044] The sealing device 3 is an axially hollow frustum shape. The protrusion of the sealing device 3 extends into the inner cavity of the annular support 1. A flow-blocking cavity is formed between the two sealing devices 3 and the annular support 1. The flow-blocking cavity guides the electrolyte at the inlet to the processing area.

[0045] The first cathode assembly includes: a first tool cathode 5, a first cathode sidewall insulation device 8, a first cathode center hole insulation device 10, a cathode clamping block 12, and a cathode mounting block 13. The second cathode assembly includes: a second tool cathode 6, a second cathode sidewall insulation device 9, a second cathode center hole insulation device 11, a cathode clamping block 12, and a cathode mounting block 13. The inner walls of the two sealing devices 3 are respectively sealed and slidably connected to the first tool cathode 5 and the second tool cathode 6. The opposing sides of the first tool cathode 5 and the second tool cathode 6 are respectively connected to the machining planes on the left and right sides of the workpiece 2. With a clearance fit, the outer ends of the first tool cathode 5 and the second tool cathode 6 are respectively detachably plugged with a first cathode sidewall insulation device 8 and a second cathode sidewall insulation device 9. Both the first cathode sidewall insulation device 8 and the second cathode sidewall insulation device 9 are made of plastic. These devices prevent stray currents from affecting non-processing areas. The first cathode sidewall insulation device 8 and the second cathode sidewall insulation device 9 are respectively provided with a first deep narrow groove 801 and a second deep narrow groove 901 that match the double-sided array blades of the eddy current generator. The narrow slots 901 extend through both sides. The inner ends of the first tool cathode 5 and the second tool cathode 6, facing each other, are respectively provided with first cathode machining edges and second cathode machining edges corresponding to the first deep narrow slot 801 and the second deep narrow slot 901. This allows the electrolyte in the machining area to enter the electrolyte output channels 1202 within the two cathode clamping blocks 12 in the opposite direction to the feed of the first tool cathode 5 and the second tool cathode 6. This design effectively improves the workpiece surface quality and machining accuracy. The outer ends of the first tool cathode 5 and the second tool cathode 6 are detachably and fixedly connected to two cathode clamping blocks 12. Two electrolyte manifolds 1201 are symmetrically opened on opposite sides of the clamping block 12. Several electrolyte output channels 1202 connected to the electrolyte manifolds 1201 are opened on the cathode clamping block 12. A cathode mounting block 13 is detachably fixedly connected to the outer end of the cathode clamping block 12. The two cathode mounting blocks 13 are detachably fixedly installed on two opposing spindles of the machine tool. The two spindles move towards or away from each other. Both cathode mounting blocks 13 are connected to the negative terminal of the machine tool power supply. The first cathode assembly and the second cathode assembly are easy to disassemble and install, and the cathodes can be replaced at any time, reducing the overall manufacturing cost of the assembly.

[0046] The machining planes on the left and right sides of the blank 2 to be processed are respectively provided with a first cathode center hole insulation device 10 and a second cathode center hole insulation device 11 between the machining planes on the left and right sides and the center holes of the first tool cathode 5 and the second tool cathode 6. Both the first cathode center hole insulation device 10 and the second cathode center hole insulation device 11 are made of plastic. The first cathode center hole insulation device 10 and the second cathode center hole insulation device 11 can ensure that the surface quality and machining accuracy of the center hole of the blank 2 to be processed are not affected by stray current during the electrolytic machining process.

[0047] It also includes: a second sealing ring 7, two of which are symmetrically arranged on the left and right sides, and the two second sealing rings 7 are respectively arranged between the first tool cathode 5 and the left sealing device 3 and the second tool cathode 6 and the right sealing device 3.

[0048] The first tool cathode 5 and the second tool cathode 6 are respectively provided with a first embedding groove and a second embedding groove on their outer ends. The first cathode sidewall insulation device 8 and the second cathode sidewall insulation device 9 are respectively detachably inserted into the first embedding groove and the second embedding groove, and are precisely positioned by two pairs of pin holes to ensure that they are on the same plane as the narrow groove sidewalls of the first cathode processing blade and the second cathode processing blade. The narrow grooves of the first cathode processing blade and the second cathode processing blade are arranged alternately to realize the alternating processing of the front and back features of the blank 2 to be processed.

[0049] An electrolytic machining method for integral forming of eddy current generator double-sided array blades, utilizing an electrolytic machining tool for integral forming of eddy current generator double-sided array blades, specifically includes the following steps:

[0050] Step 1: Place the ring support 1 fixing ring into the machine tool slot and axially position it through the two side walls of the machine tool slot. Then fix the two together with screws and connect the ring support 1 to the positive terminal of the power supply.

[0051] Step 2: Place the blank 2 to be processed on the shielding ring inside the annular support 1, use the corresponding pin hole for radial positioning, use the working surface of the shielding ring for axial positioning, and fix the blank 2 to be processed to the annular support 1 with screws.

[0052] Step 3: Place the first cathode sidewall insulation device 8 into the first embedding groove on the first tool cathode 5 and position it; place the second cathode sidewall insulation device 9 into the second embedding groove on the second tool cathode 6 and position it; position the two cathode clamping blocks 12 with the first tool cathode 5 and the second tool cathode 6 respectively, and connect them with screws; embed the first cathode center hole insulation device 10 and the second cathode center hole insulation device 11 into the center hole positions of the first tool cathode 5 and the second tool cathode 6 respectively, and connect them with screws; sleeve the two second sealing rings 7 on the opposite side of the outer wall of the first tool cathode 5 and the second tool cathode 6 respectively, move the opposite inner ends of the first tool cathode 5 and the second tool cathode 6 to the position where they are in clearance fit with the two processing planes on the left and right sides of the blank to be processed 2, and slide the two sealing devices 3 onto the outer wall of the first tool cathode 5 and the second tool cathode 6 respectively.

[0053] Step 4: Insert the two first sealing rings 4 into the side wall grooves on the left and right sides of the annular support 1 respectively, and position the two sealing devices 3 to the left and right sides of the annular support 1 through the pin holes and fix them with screws.

[0054] Step 5: Secure the two cathode mounting blocks 13 to the two cathode clamping blocks 12 on the left and right sides respectively with screws;

[0055] Step 6: Secure the two cathode mounting blocks 13 to the two opposing spindles of the machine tool with screws, level them with the machine tool work platform, and connect the negative terminal of the power supply;

[0056] Step 7: Insert the dried liquid inlet pipe into the several electrolyte inlet channels 101 corresponding to the annular support 1 and the several electrolyte outlet channels 1202 corresponding to the two cathode clamping blocks 12 respectively;

[0057] Step 8: Before starting the machine, check whether the power supply, chiller, compressed air, and electrolyte filtration system of the machine tool are normal, and check whether there are any abnormalities on the outside of the machine tool;

[0058] Step 9: After the inspection is completed, test the electrolyte and check the sealing.

[0059] Step 10: Set the eddy current electrolytic machining process parameters: electrolyte is 10% NaNO3, machining voltage is 7V, electrolyte inlet pressure is 0.8MPa, outlet pressure is 0.3MPa, electrolyte temperature is 298K, adopt the machining mode of precise matching between cathode vibration phase and pulse power output, amplitude is 0.3mm, vibration frequency is 10Hz, and conduction angle is 150°;

[0060] Step 11: Simultaneously feed the first tool cathode 5 and the second tool cathode 6 towards the blank 2 to complete the one-piece forming of the double-sided blades of the eddy current generator. After that, cut off the power, move the two spindles of the machine tool back to back a certain distance, take out the processed part, and rinse it with clean water.

[0061] Step 12: Measure and record the processed sample using a coordinate measuring machine, analyze the normal error between each point and the theoretical surface, and further correct and optimize multiple parameters through multiple experiments until the processing meets the design requirements.

[0062] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications, equivalent substitutions, and improvements made by those skilled in the art to the above embodiments without departing from the scope of the technical solution of the present invention, based on the technical essence of the present invention, shall still fall within the protection scope of the technical solution of the present invention.

Claims

1. An electrolytic machining tool for integral forming of double-sided array blades of an eddy current generator, characterized in that, include: An annular support base (1) and a blank to be processed (2) are provided. The annular support base (1) is connected to the positive terminal of the machine tool power supply. The blank to be processed (2) is detachably fixedly connected to the built-in shielding ring of the annular support base (1). Several electrolyte input channels (101) are evenly opened radially on the left and right sides of the annular support base (1). Two sealing devices (3) are symmetrically arranged on the left and right sides of the annular support base (1). The inner walls of the two sealing devices (3) are axially slidably connected to a first cathode assembly and a second cathode assembly. The first cathode assembly and the second cathode assembly move towards or away from each other. The first cathode assembly and the second cathode assembly are both connected to the negative terminal of the machine tool power supply. The working ends of the first cathode assembly and the second cathode assembly are respectively fitted with the processing planes on the left and right sides of the blank (2) to be processed. The first cathode assembly and the second cathode assembly are respectively provided with a first cathode processing blade and a second cathode processing blade that cooperate with the double-sided array blades of the eddy current generator. The first cathode assembly and the second cathode assembly are also respectively provided with a number of electrolyte output channels (1202). The electrolyte enters the gap between the first cathode assembly and the second cathode assembly and the blank (2) to be processed on the opposite side through a number of electrolyte input channels (101) on the left and right sides, and flows out through the number of electrolyte output channels on the left and right sides through the first cathode processing blade and the second cathode processing blade.The first cathode assembly includes: a first tool cathode (5), a first cathode sidewall insulation device (8), a first cathode center hole insulation device (10), a cathode clamping block (12), and a cathode mounting block (13). The second cathode assembly includes: a second tool cathode (6), a second cathode sidewall insulation device (9), a second cathode center hole insulation device (11), a cathode clamping block (12), and a cathode mounting block (13). The inner walls of the two sealing devices (3) are respectively sealed and slidably connected to the first tool cathode (5) and the second tool cathode (6). The opposing sides of the first tool cathode (5) and the second tool cathode (6) are respectively fitted with the machining planes on the left and right sides of the blank to be processed (2). The outer ends of the first tool cathode (5) and the second tool cathode (6) are respectively detachably inserted with the first cathode sidewall insulation device (8) and the second cathode sidewall insulation device (9). The first cathode sidewall insulation device (8) and the second cathode sidewall insulation device (9) are respectively provided with a first... The first deep narrow groove (801) and the second deep narrow groove (901) are both through the left and right sides. The inner ends of the first tool cathode (5) and the second tool cathode (6) facing each other are respectively provided with a first cathode processing blade and a second cathode processing blade corresponding to the first deep narrow groove (801) and the second deep narrow groove (901). The outer ends of the first tool cathode (5) and the second tool cathode (6) are respectively detachably fixedly connected to two cathode clamping blocks (12). (12) Two electrolyte manifolds (1201) are symmetrically opened on opposite sides. Several electrolyte output channels (1202) connected to the electrolyte manifolds (1201) are provided on the cathode clamping block (12). A cathode mounting block (13) is detachably fixedly connected to the outer end of the cathode clamping block (12). The two cathode mounting blocks (13) are detachably fixedly installed on two opposing spindles of the machine tool. The two spindles move towards or away from each other. Both cathode mounting blocks (13) are connected to the negative terminal of the machine tool power supply.

2. The electrolytic machining tool for integral forming of double-sided array blades of an eddy current generator according to claim 1, characterized in that: It also includes a first sealing ring (4), of which two first sealing rings (4) are provided, and the two first sealing rings (4) are respectively provided between the annular support (1) and the two sealing devices (3) on the left and right sides.

3. The electrolytic machining tool for integral forming of double-sided array blades of an eddy current generator according to claim 2, characterized in that: The annular support seat (1) is detachably fixed to the machine tool slot with an external fixing ring. The left non-machined plane of the blank to be processed (2) is in contact with the right working surface of the built-in shielding ring of the annular support seat (1).

4. The electrolytic machining tool for integral forming of double-sided array blades of an eddy current generator according to claim 3, characterized in that: The sealing device (3) is an axially hollow frustum shape, and the protrusion of the sealing device (3) extends into the inner cavity of the annular support seat (1).

5. The electrolytic machining tool for integral forming of double-sided array blades of an eddy current generator according to claim 4, characterized in that: The processing planes on the left and right sides of the blank (2) to be processed are respectively provided with a first cathode center hole insulation device (10) and a second cathode center hole insulation device (11) between the center holes of the first tool cathode (5) and the second tool cathode (6).

6. The electrolytic machining tool for integral forming of double-sided array blades of an eddy current generator according to claim 5, characterized in that: Also includes: The second sealing ring (7) is arranged symmetrically on the left and right. The two second sealing rings (7) are respectively arranged between the first tool cathode (5) and the sealing device (3) on the left and between the second tool cathode (6) and the sealing device (3) on the right.

7. The electrolytic machining tool for integral forming of double-sided array blades of an eddy current generator according to claim 6, characterized in that: The first tool cathode (5) and the second tool cathode (6) are respectively provided with a first embedding groove and a second embedding groove on their outer ends. The first cathode sidewall insulation device (8) and the second cathode sidewall insulation device (9) are respectively detachably inserted into the first embedding groove and the second embedding groove.

8. A method for electrolytic machining of integral forming of double-sided array blades of a vortex generator, using the electrolytic machining tool for integral forming of double-sided array blades of a vortex generator as described in claim 7, characterized in that: Specifically, it includes the following steps: Step Step 1: Place the ring support (1) fixing ring in the machine tool slot and axially position it through the two side walls of the machine tool slot. Then fix the two together with screws and connect the ring support (1) to the positive terminal of the power supply. Step 2: Place the blank (2) to be processed on the shielding ring inside the ring support (1), use the corresponding pin hole for radial positioning, use the working surface of the shielding ring for axial positioning, and fix the blank (2) to be processed and the ring support (1) together with screws. Step 3: Place the first cathode sidewall insulation device (8) in the first embedded groove on the first tool cathode (5) and position it. Place the second cathode sidewall insulation device (9) in the second embedded groove on the second tool cathode (6). Set up the groove and position it; position the two cathode clamping blocks (12) with the first tool cathode (5) and the second tool cathode (6) respectively, and connect them with screws; embed the first cathode center hole insulation device (10) and the second cathode center hole insulation device (11) into the center hole positions of the first tool cathode (5) and the second tool cathode (6) respectively, and connect them with screws; put the two second sealing rings (7) onto the opposite side of the outer wall of the first tool cathode (5) and the second tool cathode (6) respectively, and move the opposite inner ends of the first tool cathode (5) and the second tool cathode (6) to the position where they fit the gap between the two processing planes on the left and right sides of the blank to be processed (2), and put the two sealing rings into place. The device (3) is slidably fitted onto the outer walls of the first tool cathode (5) and the second tool cathode (6); Step 4: Insert the two first sealing rings (4) into the side wall grooves on the left and right sides of the annular support (1), and position the two sealing devices (3) and the left and right sides of the annular support (1) through pin holes and fix them with screws; Step 5: Fix the two cathode mounting blocks (13) to the two cathode clamping blocks (12) on the left and right sides with screws; Step 6: Fix the two cathode mounting blocks (13) to the two opposing spindles of the machine tool with screws, and level them with the machine tool working platform, and connect the negative terminal of the power supply; Step 7: Insert the dry liquid pipe into the annular support. The support (1) has several electrolyte input channels (101) and the two cathode clamping blocks (12) have several electrolyte output channels (1202) respectively; Step 8: Before starting the machine, check whether the machine tool power supply, chiller, compressed air and electrolyte filtration system are normal, and check whether there are any abnormalities on the outside of the machine tool; Step 9: After the inspection, try to turn on the electrolyte and check the sealing condition; Step 10: Set the eddy current electrolytic machining process parameters: the electrolyte is 10% NaNO3, the machining voltage is 7V, the electrolyte inlet pressure is 0.8MPa, the outlet pressure is 0.3MPa, the electrolyte temperature is 298K, and the cathode vibration phase and pulse power output are precisely matched in the machining mode, with an amplitude of 0.3mm, vibration frequency of 10Hz, conduction angle of 150°; Step 11: feed the first tool cathode (5) and the second tool cathode (6) simultaneously toward the blank (2) to be processed. After completing the integral forming of the double-sided blades of the eddy current generator, cut off the power supply, move the two spindles of the machine tool a certain distance away from each other, take out the processed parts, and rinse them with clean water; Step 12: Measure and record the processed sample using a coordinate measuring machine, analyze the normal error between each point and the theoretical surface, and further correct and optimize multiple parameters through multiple experiments until the processing meets the design requirements.

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