整体叶盘套形电解加工绝缘套优化方法研究

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关键词：套形电解加工；薄壁叶片；绝缘套；流固耦合仿真；正交试验中图分类号：V26DOI：10.3969/j.issn.1004-132X.2026.02.015 开放科学（资源服务）标识码（OSID）：

Optimization Method of Insulating Sleeves in Electrochemical Trepanning for Disks

WANG Yunmiao1 ZHU Dongl JIAO Erhao1 WANG Huan² ZHANG Chao1² WANG Ruolong1

1.College of Mechanical &. Electrical Engineering，Nanjing University of Aeronautics and Astronautic， Nanjing，210016 2.Beijing Power Machinery Institute，Beijing ，100074

Abstract：Reducing the deformations of the insulating sleeves during the ECT processes was an important method to improve the stability and accuracy of ECT. This paper proposed an optimization method for the insulating sleeves.With a thin-walled blade of chord length 20mm ，blade height 23mm ，and blade thickness 0.54mm as an example，tool cathode models with different insulating sleeve structures were es- tablished，FSI simulations were conducted，and the structural parameters of the insulating sleeve reinforcement ribs were optimized. Compared with the insulating sleeves without reinforcement ribs，the maximum deformation of the optimized insulating sleeves is reduced from 0.261mm to 0.020mm ，and the velocity distribution in the machining area becomes more uniform. ECT experiments were carried out on thinwalled blades with insulating sleeve reinforcement widths of 0mm ， 1mm ， 2mm ，and 4.5mm respectively.The results show that，compared with the insulating sleeve without reinforcement ribs，the value of surface roughness of the machined blades with a reinforcement width of 4.5mm is reduced from 1.81μm to 1.05μm . The method was verified to be effective in reducing the deformations of the insulating sleeve and improving the stability of ECT.

Key words：electrochemical trepanning（ECT）；thin-walled blade；insulating sleeve；fluid-structure interaction（FSI） simulation；orthogonal experiment

0 引言

整体叶盘等整体构件是航空航天发动机压气机的核心零部件，叶片数量高达几十甚至上百个，具有叶片薄易变形、加工通道狭窄等特点[1-3]，采用传统机械加工方式存在刀具磨损严重、加工成本高等缺点4]。（剩余12095字）