Design and Optimization of Flow Field in Electrochemical Trepanning for Double Blades

Diffuser with double blades（main blade and splitter blade） can further optimize the performance of compressor and is widely used in air engines. For these components made by difficult-cutting materials, traditional milling is easy to cause the loss of tools. Electrochemical machining technology（ECM） has the characteristics of no mechanical cutting force and wide machining range.A method of electrochemical trepanning for double blades is proposed. The liquid outlet channel（LOC） between blades is design based on the equal-distance of flow path. The 3D flow channel models with increasing width of LOC are established and CFD simulations are carried out. When the width is 0.9 mm, the electrolyte in the machining area has the most uniform flow rate. The results of comparative experiments with GH4169 material showed that the cathode feed rate is increased from 0.5 mm/min to 1mm/min, and the material removal rate reached 1 396.5 mm3/min. The surface morphology of the hub is improved and the blade taper was reduced to less than 1:14.29.