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《Journal of Southeast University(Natural Science Edition)》 2010-05
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Accuracy analysis and error compensation on electrochemical sweep-forming of integral blisk

Wang Fuyuan1,2 Xu Jiawen1 Zhao Jianshe1(1College of Mechanical and Electrical Engineering,Nanjing University of Aeronautics and Astronautics,Nanjing 210016,China)(2College of Mechanical Engineering,Yancheng Institute of Technology,Yancheng 224051,China)  
In order to improve the electrochemical machining(ECM) accuracy of the blade of integral blisk,the causes resulted in machining errors are analyzed in past adopted processes.The computation formulas of the errors caused by the motion of machine tool,numerical control program and initial gap of cathode are deduced.The computer simulation method is used to simulate the ECM course of the blade and the distribution of error arising from the overcut of ECM is obtained.It is found that the error increases with the twist angel of blade.On these bases,a new machining process of fraction step is proposed.In the process the machining errors of the blade can be effectively compensated by different methods.The experiment shows that the machining tolerance can be controlled within 0.1mm by using fraction step process and error compensation.The blade root is machined individually,thus the over-cutting can be eliminated.The applications of the fraction step process and the compensation measures obviously enhance the ECM accuracy of the blade.The accuracy of the machined blade can meet the need of the ECM procedure.
【Fund】: 国家自然科学基金资助项目(50675103);; 国防科技工业“十一五”科技发展规划资助项目;; 江苏省高校自然科学研究计划资助项目(08KJB460007)
【CateGory Index】: TG661
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