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反拷法电解加工涉及不可逆的二次电解加工过程,加工精度很难控制,无法满足航空发动机叶片的制造需求。在分析反拷法电解加工误差产生原因的基础上,以提升加工精度为目的,提出了小加工间隙反拷法电解加工方法。以加工典型的航空发动机叶片为例,开展不同加工间隙条件下的反拷法电解加工对比实验,结果表明:加工间隙由拷贝工具0.49 mm/反拷工件0.53 mm减小至拷贝工具0.23 mm/反拷工件0.23 mm,叶片型面轮廓精度由0.14 mm提升至0.05 mm,该结果验证了提出方法的有效性。
Anti-copy electrolytic machining involves irreversible secondary electrolytic machining process, the processing accuracy is difficult to control, can not meet the manufacturing needs of aviation engine blades. Based on the analysis of the causes of the error in the anti-copy electrolytic machining and the purpose of improving the machining accuracy, a small machining gap anti-copy electrolytic machining method is proposed. Taking the processing of typical aero-engine blades as an example, comparative experiments of anti-copy electrolytic machining under different processing gap conditions were carried out. The results showed that the processing gap was reduced from 0.49 mm for copy tool to 0.53 mm for anti-copy workpiece to 0.23 mm for anti-copy tool The result showed that the proposed method was validated by copying the workpiece 0.23 mm and increasing the profile accuracy of the blade profile from 0.14 mm to 0.05 mm.