A multi-tool blisk pulsating precision electrolytic machining method

Abstract

The application discloses a kind of multi-tool integral blade disc pulsation precision electrolytic processing methods, it is related to electrolytic processing technical field, comprising the following steps: step one, design and install tool cathode, complete the design of blade pan cathode and blade back cathode, blade pan cathode and blade back cathode are installed on blade pan tool disc and blade back tool disc;Step two, tool setting, through blade pan feeding device drive blade pan tool disc rotates clockwise around integral blade disc axial;Through blade back feeding device drive blade back tool disc rotates counterclockwise around integral blade disc axial;Step three, multi-blade profile pulsation state electrolytic processing, positive pole of pulse power supply is integral blade disc power supply, negative pole of pulse power supply is blade pan cathode and blade back cathode power supply, set electrolytic processing parameter, electrolyte is passed in, blade back cathode and blade pan cathode are fed to blade;Step four, tool setting is withdrawn and integral blade disc is indexed, when a group of blades processing is finished, enter the processing of next group of blade profile.The application can provide integral blade disc processing efficiency.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electrolytic machining, in particular to a multi-tool blisk pulsating precision electrolytic machining method. BACKGROUND

[0002] As a core component in an aero-engine, a blisk and other monolithic components play an irreplaceable role. The blisk is a monolithic component composed of blades and a disk. Compared with the traditional assembly structure, the blisk reduces the weight of the parts and eliminates the airflow loss at the joint of the tenon and groove, and is a core component of the aero-engine. Using the traditional numerical control mechanical machining method to machine the blisk has the disadvantages of low machining efficiency, long machining cycle and tool wear, which seriously affects the batch production of the engine.

[0003] Electrochemical machining is based on the principle of anodic electrochemical dissolution of metal materials to achieve material removal. It has the advantages of no tool wear, high machining efficiency, no material hardness limitation, no residual stress and good machining surface quality, and has significant advantages in machining blisks.

[0004] In the existing blisk electrolytic machining, a single electrode is usually used to machine a single blade. With the increasing task load of actual production needs, the existing single-channel electrolytic machining cannot meet the actual needs, so innovation is needed in the electrolytic machining method and machining device to achieve efficient machining of multiple tools.

[0005] In the invention patent "Blisk cascade group electrode electrolytic machining device and method", a plurality of circumferential array cathodes are used to feed along the radial direction of the blisk, and the rotation of the composite tool cathode is used to realize the machining of multiple cascade channels. In the invention patent "Blisk multi-channel electrolytic machining device and machining method", the self-yawing of the circumferential array of circular pipe electrodes and the superposition of the spiral motion of the blisk are used to realize the machining and forming of multiple inter-blade channels. These invention patents have greatly improved the efficiency of traditional blisk electrolytic machining, but these methods can only achieve rough machining of the blisk, and the blade profile obtained needs to be further machined. The traditional precision machining of the blade profile of the blisk usually uses a pair of blade basin and blade back cathodes to realize bidirectional feeding. After machining a blade, the blisk is indexed, and the electrolytic machining of the next blade can be performed. However, this machining process can only realize single-blade machining, and still needs to repeat the feeding and retreating multiple times, which has the problem of long machining cycle.

[0006] Therefore, there is an urgent need in the art for a multi-tool blisk pulsating precision electrolytic machining method to solve the above problems. SUMMARY

[0007] The present application aims to provide a multi-tool integral blade disk pulsating dynamic precision electrolytic machining method, which can simultaneously realize the finishing machining of multiple blade profiles and improve the machining efficiency of integral blade disks.

[0008] To achieve the above-mentioned purpose, the present application provides the following solutions.

[0009] The present application discloses a multi-tool integral blade disk pulsating dynamic precision electrolytic machining method, which comprises the following steps.

[0010] Step one, design and install tool cathode, first, design the angle of the installation angle of the blade back cathode, the angle of the installation angle of the blade basin cathode, the thickness of the blade back cathode and the thickness of the blade basin cathode according to the blade profile of the integral blade disk to be machined and the structure of the finished blade row channel, then determine the shape of the blade back cathode machining surface and the blade basin cathode machining surface, and finally complete the structural design of the blade basin cathode and the blade back cathode, and install the blade basin cathode and the blade back cathode on the blade basin tool disk and the blade back tool disk according to the circumferential distribution law and the installation inclination angle of the blades of the integral blade disk.

[0011] Step two, tool setting, drive the blade basin tool disk to rotate clockwise around the axis of the integral blade disk through the blade basin feeding device, so that the blade basin cathode is reserved with a certain machining gap from the blade; at the same time, drive the blade back tool disk to rotate counterclockwise around the axis of the integral blade disk through the blade back feeding device, so that the blade back cathode is reserved with a certain machining gap from the blade.

[0012] Step three, multi-blade profile pulsating dynamic electrolytic machining, the positive electrode of the pulse power supply is used to power the integral blade disk, the negative electrode of the pulse power supply is used to power the blade basin cathode and the blade back cathode, electrolytic machining parameters are set, electrolyte is introduced, the blade basin tool disk is driven to rotate counterclockwise by the blade basin feeding device, so that the circumferential array of blade basin cathode machining surfaces is close to the blade basin profile; the blade back tool disk is driven to rotate clockwise by the blade back feeding device, so that the circumferential array of blade back cathode machining surfaces is close to one side of the blade back profile; while the blade back cathode and the blade basin cathode are fed to the blade, the blade basin cathode and the blade back cathode are respectively reciprocatingly vibrated along the circumference to the blade under the driving of the blade basin vibrator and the blade back vibrator, and the blade back cathode and the blade basin cathode are respectively applied with pulse voltage between them and the integral blade disk, so as to realize the pulsating dynamic electrolytic machining of the blade profile.

[0013] Step four, tool retraction and integral blade disk indexing, after the machining of a group of blades is completed, power off and stop liquid introduction, the blade basin cathode and the blade back cathode are respectively withdrawn from the blade row channel, the integral blade disk is rotated by a certain angle around its own axis, and enters the machining of the next group of blade profiles, until the machining and forming of all blade profiles are completed.

[0014] Preferably, in step three, when the distance between the blade pan cathode and the whole blade disc and the distance between the blade back cathode and the whole blade disc are 0.1mm, the pulse power supply is powered on, and the workpiece material is electrochemically dissolved; when the distance between the blade pan cathode and the whole blade disc and the distance between the blade back cathode and the whole blade disc are 1mm, the pulse power supply is turned off, and the workpiece material is not dissolved, and the flowing electrolyte can carry away the electrolysis products and Joule heat.

[0015] Preferably, the moving end of the blade pan feeding device is connected with the blade pan vibrator, the blade pan vibrator is fixed with a blade pan connecting block, the first end of a blade pan connecting rod is hinged to the blade pan connecting block through a blade pan first hinge shaft, and the second end of the blade pan connecting rod is hinged to the blade pan tool disc through a blade pan second hinge shaft.

[0016] The moving end of the blade back feeding device is connected with the blade back vibrator, the blade back vibrator is fixed with a blade back connecting block, the first end of a blade back connecting rod is hinged to the blade back connecting block through a blade back first hinge shaft, and the second end of the blade back connecting rod is hinged to the blade back tool disc through a blade back second hinge shaft.

[0017] Preferably, the whole blade disc can be fixed on a fixed inner column, the fixed inner column can pass through the centers of the blade pan tool disc and the blade back tool disc, the blade pan tool disc and the blade back tool disc are rotationally connected with the fixed inner column, and the axis of the whole blade disc, the axis of the blade back tool disc and the axis of the blade pan tool disc are collinear.

[0018] Preferably, the negative electrode of the pulse power supply is electrically connected with the blade pan cathode and the blade back cathode through wires respectively.

[0019] Preferably, an insulating layer or an insulating sheet is arranged between the blade back cathode and the blade back tool disc and between the blade pan cathode and the blade pan tool disc.

[0020] Preferably, one blade pan cathode or one blade back cathode can be placed in each vane channel.

[0021] The number of the blade back cathodes and the number of the blade pan cathodes are half of the number of the blades.

[0022] Preferably, the surfaces of the blade pan cathode and the blade back cathode except the blade pan cathode machining surface and the blade back cathode machining surface are coated with epoxy resin.

[0023] The present application has the following technical effects compared with the prior art:

[0024] The application adopts multiple blade-pot cathodes and blade-back cathodes to process half blades of the whole blade disc simultaneously, compared with the traditional single electrode processing one by one, the whole blade disc is formed once by twice processing, the processing efficiency of the whole blade disc is greatly improved, the manufacturing cycle is greatly shortened, and the advantages of high efficiency, low cost and tool non-waste of electrolytic processing are fully played;

[0025] Further, the application designs a transmission mechanism for converting linear motion into circumferential vibration of the tool cathode, realizes the opposite rotation and circumferential micro-vibration motion of the circumferentially arranged blade-pot cathode and blade-back cathode, and thus completes the pulse electrochemical machining forming of multiple blade profiles. The mechanism simplifies the structure of the electrolytic processing machine tool and reduces the equipment cost, and has great potential benefits. The method of the application is also applicable to the synchronous electrolytic processing of blade profiles of closed blade rings, rectifiers and other whole components, and has strong process applicability;

[0026] Further, the application uses pulse vibration to optimize the pulse electrochemical machining mode, realizes small-gap processing, and improves the processing precision and stability. The vibration device realizes the circumferential vibration feeding of the tool cathode. The pulse electrochemical machining promotes the timely discharge of electrolysis products and Joule heat, and thus ensures the micro-gap processing of the processing area under the high-frequency pulse voltage, effectively improves the processing precision and surface quality of the blade. BRIEF DESCRIPTION OF DRAWINGS

[0027] In order to more clearly illustrate the technical solutions in the embodiments of the application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments. Obviously, the drawings in the following description only constitute some embodiments of the application, and for those skilled in the art, other drawings can also be obtained without creative labor based on these drawings.

[0028] Figure 1 The device structure diagram of the multi-tool whole blade disc pulse electrochemical machining method of the embodiment of the application;

[0029] Figure 2 The blade-pot tool disc structure schematic diagram in the multi-tool whole blade disc pulse electrochemical machining method of the embodiment of the application;

[0030] Figure 3 The blade-back tool disc structure schematic diagram in the multi-tool whole blade disc pulse electrochemical machining method of the embodiment of the application;

[0031] Figure 4 The power supply connection diagram in the multi-tool whole blade disc pulse electrochemical machining method of the embodiment of the application;

[0032] Figure 5An electrolytic machining local view in the multi-tool blisk pulsating state precision electrolytic machining method of the embodiment of the present application;

[0033] Figure 6 A structure schematic view of the blade pan tool disc in the multi-tool blisk pulsating state precision electrolytic machining method of the embodiment of the present application;

[0034] Figure 7 A movement schematic view of the blade pan tool disc in the multi-tool blisk pulsating state precision electrolytic machining method of the embodiment of the present application;

[0035] In the figure: 1, blade pan cathode; 1-1, blade pan cathode machining surface; 2, blade pan tool disc; 2-1, blade pan cathode installation angle; 3, blade back cathode; 3-1, blade back cathode machining surface; 4, blade back tool disc; 4-1, blade back cathode installation angle; 5, blisk; 6, fixed inner column; 7, blade pan feeding device; 8, blade pan vibrator; 9, blade pan connecting block; 10, blade pan first hinged shaft; 11, blade pan second hinged shaft; 12, blade pan connecting rod; 13, blade back feeding device; 14, blade back vibrator; 15, blade back connecting block; 16, blade back connecting rod. DETAILED DESCRIPTION

[0036] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the present application.

[0037] The purpose of the present application is to provide a multi-tool blisk pulsating state precision electrolytic machining method, which can solve the technical problems in the prior art and realize the precision machining of multiple blade profiles at the same time, thereby improving the machining efficiency of the blisk.

[0038] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the present application will be further described in detail below with reference to the drawings and specific embodiments.

[0039] As Figures 1-7 shown, the present embodiment provides a multi-tool blisk pulsating state precision electrolytic machining method, which comprises the following steps:

[0040] Step one, design and install tool cathode: first, according to the blade profile of the whole blade disk 5 to be processed and the rough machining completed blade channel structure, the angle of the blade back cathode installation angle 4-1, the angle of the blade back cathode installation angle 2-1, the thickness of the blade back cathode 3 and the thickness of the blade back cathode 1 are designed, then the shape of the blade back cathode processing surface 3-1 and the blade back cathode processing surface 1-1 is determined, and finally the structure design of the blade back cathode 1 and the blade back cathode 3 is completed. The blade back cathode 1 and the blade back cathode 3 are installed on the blade back tool disc 2 and the blade back tool disc 4 according to the circumferential distribution rule and the installation inclination angle of the blade of the whole blade disk 5.

[0041] Step two, tool setting: the blade back tool disc 2 is driven by the blade back feeding device 7 to rotate clockwise around the whole blade disk 5, so that the blade back cathode 1 is reserved a certain machining gap with the blade; at the same time, the blade back tool disc 4 is driven by the blade back feeding device 13 to rotate counterclockwise around the whole blade disk 5, so that the blade back cathode 3 is reserved a certain machining gap with the blade.

[0042] Step three, multi-blade profile pulsating electrochemical machining: the positive electrode of the pulse power supply is connected to the whole blade disk 5, and the negative electrode of the pulse power supply is connected to the blade back cathode 1 and the blade back cathode 3. The electrolyte is set and flowed. The blade back tool disc 2 is driven by the blade back feeding device 7 to rotate counterclockwise, so that the circumferential array of the blade back cathode processing surface 1-1 is close to the blade back surface of the blade. The blade back tool disc 4 is driven by the blade back feeding device 13 to rotate clockwise, so that the circumferential array of the blade back cathode processing surface 3-1 is close to one side of the blade back surface of the blade. At the same time, the blade back cathode 3 and the blade back cathode 1 are respectively vibrated along the circumferential direction to the blade under the action of the blade back vibrator 14 and the blade back vibrator 8, and the blade back cathode 3 and the blade back cathode 1 are respectively connected to the whole blade disk 5 to apply pulse voltage, so as to realize the pulsating electrochemical machining of the blade profile.

[0043] Step four, tool retraction and whole blade disk 5 indexing: after the machining of a group of blades is completed, the power is turned off and the electrolyte is stopped flowing, the blade back cathode 1 and the blade back cathode 3 are withdrawn from the blade channel, and the whole blade disk 5 is rotated around its own axis by a certain angle to enter the machining of the next group of blade profiles until the machining of all blade profiles is completed.

[0044] In this embodiment, in step three, through the phase coupling of pulse vibration, when the distance between the blade back cathode 1 and the blade back cathode 3 and the whole blade disk 5 is about 0.1mm, the pulse power supply is powered on, and the workpiece material (i.e. the whole blade disk 5) is electrochemically dissolved. When the distance between the blade back cathode 1 and the blade back cathode 3 and the whole blade disk 5 is 1mm, the pulse power supply is turned off, and the workpiece material (i.e. the whole blade disk 5) is not dissolved, and the flowing electrolyte can carry away the electrolysis products and Joule heat.

[0045] In the embodiment, the moving end of the vane pan feeding device 7 is connected with a vane pan vibrator 8, the vane pan vibrator 8 is fixed with a vane pan connecting block 9, the vane pan connecting block 9 is hinged with the first end of a vane pan connecting rod 12 through a vane pan first hinging shaft 10, and the second end of the vane pan connecting rod 12 is hinged with the vane tool disc 2 through a vane pan second hinging shaft 11.

[0046] In actual work, the vane pan vibrator 8 is driven to move laterally by the vane pan feeding device 7, and since the vane pan vibrator 8 is hinged with the vane tool disc 2 through the vane pan connecting rod 12, the vane tool disc 2 can be driven to rotate in a small range. The vane tool disc 2 can be vibrated by the vane pan vibrator 8, so as to realize the vibration feeding of the vane cathode 1.

[0047] The vane back feeding device 13 has the same structure as the vane pan feeding device 7. Specifically, the moving end of the vane back feeding device 13 is connected with a vane back vibrator 14, the vane back vibrator 14 is fixed with a vane back connecting block 15, the vane back connecting block 15 is hinged with the first end of a vane back connecting rod 16 through a vane back first hinging shaft, and the second end of the vane back connecting rod 16 is hinged with the vane back tool disc 4 through a vane back second hinging shaft.

[0048] Further, the vane pan feeding device 7 and the vane back feeding device 13 include but are not limited to existing linear motors, hydraulic cylinders or air cylinders, etc. The vane back vibrator 14 and the vane pan vibrator 8 include but are not limited to existing vibrators, excitation vibrators, vibration motors or vibration motors.

[0049] In the embodiment, the whole vane disc 5 can be fixed on the fixed inner column 6. In the vane profile finishing, the whole vane disc 5 and the fixed inner column 6 do not rotate, the fixed inner column 6 can pass through the center of the vane tool disc 2 and the vane back tool disc 4, and the whole vane disc 5 can be located in the middle of the vane tool disc 2 and the vane back tool disc 4. The vane tool disc 2 and the vane back tool disc 4 are rotationally connected with the fixed inner column 6 through rotation bearings, that is, the vane tool disc 2 and the vane back tool disc 4 do not drive the fixed inner column 6 to rotate when rotating. In addition, the axis of the whole vane disc 5, the axis of the vane back tool disc 4 and the axis of the vane tool disc 2 are collinear.

[0050] In the embodiment, there are two connection modes of the negative pole of the pulse power supply for supplying power to the vane cathode 1 and the vane back cathode 3.

[0051] One is that the negative pole of the pulse power supply is connected with the vane tool disc 2 and the vane back tool disc 4 through wires, and then the vane tool disc 2 and the vane back tool disc 4 supply power to the vane cathode 1 or the vane back cathode 3 respectively.

[0052] The other is that the negative pole of the pulse power supply is connected with the vane cathode 1 and the vane back cathode 3 through wires. In this case, the pulse power supply directly supplies power to the vane cathode 1 and the vane back cathode 3, and each vane cathode 1 and vane back cathode 3 is independently powered. The embodiment preferably adopts this connection mode.

[0053] In the embodiment, when the pulse power is directly used to supply power to the vane base cathode 1 and the vane back cathode 3, an insulating layer or an insulating sheet is arranged between the vane back cathode 3 and the vane back tool disc 4 and between the vane base cathode 1 and the vane base tool disc 2. The insulating layer is made of epoxy resin or ceramic coating, and the insulating sheet is made of epoxy resin or PEEK, so as to avoid the conduction of the vane base tool disc 2 and the vane back tool disc 4.

[0054] In the embodiment, one vane base cathode 1 or one vane back cathode 3 can be placed in each vane channel, and the vane base cathode 1 and the vane back cathode 3 in adjacent vane channels are arranged in turn.

[0055] The number of the vane base cathode 1 and the number of the vane back cathode 3 are each half of the number of the blades, and each time the tool is fed to realize the profile finishing of half of the blades.

[0056] In the embodiment, the vane base cathode machining surface 1-1 and the vane back cathode machining surface 3-1 are designed according to the actual vane channel structure and the electrolytic forming rule, and the other surfaces of the vane base cathode 1 except the vane base cathode machining surface 1-1 and the other surfaces of the vane back cathode 3 except the vane back cathode machining surface 3-1 are coated with epoxy resin, so as to avoid the conduction of other places.

[0057] The principles and implementation manners of the present application are described in the specification by using specific examples, and the above description of the embodiments is only used to help understand the method of the present application and its core idea; meanwhile, for those skilled in the art, according to the idea of the present application, the specific implementation manners and application ranges will be changed. In conclusion, the content of the specification should not be understood as the limitation of the present application.

Claims

1. A method for precision electrochemical machining of a multi-tool blisk pulsating surface, characterized in that, The method comprises the following steps: Step one, design and install tool cathode, first, according to the blade profile of the whole blade disk to be processed and the channel structure of the rough machining completed blade row, design the angle of the installation angle of the blade back cathode, the angle of the installation angle of the blade back cathode, the thickness of the blade back cathode and the thickness of the blade back cathode, then determine the shape of the blade back cathode processing surface and the blade back cathode processing surface, finally complete the structure design of the blade back cathode and the blade back cathode, and install the blade back cathode and the blade back cathode on the blade back tool disc and the blade back tool disc according to the circumferential distribution rule and the installation inclination angle of the blade of the whole blade disk; Step two, tool setting, drive the blade back tool disc to rotate clockwise around the whole blade disk through the blade back feeding device, so that the blade back cathode and the blade back cathode are reserved a certain machining gap; at the same time, drive the blade back tool disc to rotate counterclockwise around the whole blade disk through the blade back feeding device, so that the blade back cathode and the blade back cathode are reserved a certain machining gap; Step three, multi-blade profile pulsating electrochemical machining, the positive electrode of the pulse power supply is used for power supply of the whole blade disk, the negative electrode of the pulse power supply is used for power supply of the blade back cathode and the blade back cathode, the electrolytic machining parameters are set, the electrolyte is introduced, the blade back tool disc is driven to rotate counterclockwise by the blade back feeding device, so that the circumferential array of the blade back cathode processing surface is close to the blade back surface profile; the blade back feeding device drives the blade back tool disc to rotate clockwise, so that the circumferential array of the blade back cathode processing surface is close to one side of the blade back surface profile; while the blade back cathode and the blade back cathode feed to the blade, the blade back cathode and the blade back cathode are respectively driven to reciprocatingly vibrate and feed along the circumference by the blade back vibrator and the blade back vibrator, and the blade back cathode and the blade back cathode are respectively applied with pulse voltage between the blade back cathode and the blade back cathode, so as to realize the pulsating electrochemical machining of the blade profile; Step four, tool retraction and whole blade disk indexing, after a group of blades are machined, power off and stop liquid, the blade back cathode and the blade back cathode are respectively withdrawn from the blade row channel, the whole blade disk rotates around its own axis by a certain angle, enters the machining of the next group of blade profiles, and finally completes the machining and forming of all blade profiles.

2. The method of claim 1, wherein the method is characterized by: In step three, when the distance between the blade back cathode and the blade back cathode and the whole blade disk is 0.1mm, the pulse power supply is powered on, and the workpiece material is electrochemically dissolved; when the distance between the blade back cathode and the blade back cathode and the whole blade disk is 1mm, the pulse power supply is turned off, and the workpiece material is not dissolved, and the flowing electrolyte can carry away the electrolysis products and Joule heat.

3. The method of claim 1, wherein the method further comprises: providing a plurality of tools; and providing a plurality of holes in the disk. The moving end of the blade back feeding device is connected with the blade back vibrator, the blade back vibrator is fixed with a blade back connecting block, the blade back connecting block is hinged with the first end of a blade back connecting rod through a blade back first hinge shaft, and the second end of the blade back connecting rod is hinged with the blade back tool disc through a blade back second hinge shaft. The moving end of the trailing edge feeding device is connected with the trailing edge vibrator, the trailing edge vibrator is fixed with a trailing edge connecting block, the trailing edge connecting block is hinged with the first end of a trailing edge connecting rod through a trailing edge first hinging shaft, and the second end of the trailing edge connecting rod is hinged with the trailing edge tool disc through a trailing edge second hinging shaft.

4. The method of claim 1, wherein the method further comprises: providing a plurality of tools; and providing a plurality of holes in the plurality of tools. The integral blade disc can be fixed on a fixed inner column which can pass through the center of the trailing edge tool disc and the leading edge tool disc, and the trailing edge tool disc and the leading edge tool disc are rotationally connected with the fixed inner column, and the axis of the integral blade disc, the axis of the trailing edge tool disc and the axis of the leading edge tool disc are collinear.

5. The method of claim 1, wherein the method further comprises: providing a plurality of tools on the disk; and providing a plurality of electrolyte channels on the disk. The negative pole of the pulse power supply is electrically connected with the leading edge cathode and the trailing edge cathode through wires respectively.

6. The method of claim 1, wherein the method further comprises: providing a plurality of tools on the disk; and providing a plurality of electrolyte channels on the disk. An insulating layer or an insulating sheet is arranged between the trailing edge cathode and the trailing edge tool disc and between the leading edge cathode and the leading edge tool disc.

7. The method of claim 1, wherein the method further comprises: providing a plurality of tools on the disk; and providing a plurality of electrolyte channels on the disk. One leading edge cathode or one trailing edge cathode can be placed in each of the blade row channels. The number of the leading edge cathodes and the number of the trailing edge cathodes are half of the number of the blades.

8. The method of claim 1, wherein the method further comprises: providing a plurality of tools on the disk; and providing a plurality of electrolyte channels on the disk. The surfaces of the leading edge cathode except the processing surface of the leading edge cathode and the surfaces of the trailing edge cathode except the processing surface of the trailing edge cathode are coated with epoxy resin.

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