Precision wire electrochemical machining of thick structures in powder superalloy René 88DT using a partially insulated tube electrode

doi:10.1007/s40436-023-00441-5

Advances in Manufacturing ›› 2023, Vol. 11 ›› Issue (4): 618-635.doi: 10.1007/s40436-023-00441-5

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Precision wire electrochemical machining of thick structures in powder superalloy René 88DT using a partially insulated tube electrode

Cheng Tang, Zhao Han, Zhong-Qi Zhou, Xiao-Long Fang

Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People's Republic of China

收稿日期:2022-08-14 修回日期:2022-10-31 发布日期:2023-10-27
通讯作者: Xiao-Long Fang,E-mail:xlfang@nuaa.edu.cn E-mail:xlfang@nuaa.edu.cn
作者简介:Cheng Tang is a Master student at Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology, Nanjing University of Aeronautics and Astronautics. His research interests include wire electrochemical machining and micro-electrochemical machining.
Zhao Han is a Ph.D. candidate at Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology, Nanjing University of Aeronautics and Astronautics. His research interests include wire electrochemical machining and wire electrical discharge machining.
Zhong-Qi Zhou is a Ph.D. candidate at Jiangsu Key Laboratory of Precision and MicroManufacturing Technology, Nanjing University of Aeronautics and Astronautics. His research interests include wire electrochemical machining and micro-electrochemical machining.
Xiao-Long Fang is a professor and doctoral supervisor at Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology, Nanjing University of Aeronautics and Astronautics. His research interests include electrochemical drilling, wire electrochemical machining, and micro-electrochemical machining. He was selected into Young Elite Scientist Sponsorship Program of China Association for Science and Technology in 2020.
基金资助:
This project was supported by the National Natural Science Foundation of China (Grant No. 51975291), the Science Center for Gas Turbine Project (Grant No. P2022-B-IV-010-001), and the Natural Science Foundation of Jiangsu Province (Grant No. BK20191279).

Precision wire electrochemical machining of thick structures in powder superalloy René 88DT using a partially insulated tube electrode

Cheng Tang, Zhao Han, Zhong-Qi Zhou, Xiao-Long Fang

Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People's Republic of China

Received:2022-08-14 Revised:2022-10-31 Published:2023-10-27
Contact: Xiao-Long Fang,E-mail:xlfang@nuaa.edu.cn E-mail:xlfang@nuaa.edu.cn
Supported by:
This project was supported by the National Natural Science Foundation of China (Grant No. 51975291), the Science Center for Gas Turbine Project (Grant No. P2022-B-IV-010-001), and the Natural Science Foundation of Jiangsu Province (Grant No. BK20191279).

摘要/Abstract

摘要： Wire electrochemical machining (WECM) is a potential method for manufacturing macrostructures from difficult-to-cut materials, such as turbine slots, with good surface integrity and low costs. In this study, a novel tube electrode with array holes in the front and insulation in the back was applied using WECM to improve the machining precision and efficiency. Additionally, assisted by an immersion electrolyte and axial flushing, the electrolyte-deficient gap was supplemented to achieve the cutting of a very thick workpiece. The simulation results indicated that this method could effectively reduce the machining gap and improve the uniformity of the electric- and flow-field distributions. Experiments verified that when the uninsulated range (machining angle) was reduced from 360° to 90°, the side machining gap was reduced from 462.5 μm to 175 μm. Finally, using optimized machining parameters, array slits with gaps as small as (175±10) μm were machined on a powder superalloy René 88DT sample with a thickness of 10 mm at a feed rate of 16 μm/s. The feasibility of fabricating complex profiles using this method was verified using a self-designed servo device.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00441-5

关键词: Wire electrochemical machining (WECM), Tube electrode, Partial insulation, Machining angle, Electrolyte flushing, Surface quality

Abstract: Wire electrochemical machining (WECM) is a potential method for manufacturing macrostructures from difficult-to-cut materials, such as turbine slots, with good surface integrity and low costs. In this study, a novel tube electrode with array holes in the front and insulation in the back was applied using WECM to improve the machining precision and efficiency. Additionally, assisted by an immersion electrolyte and axial flushing, the electrolyte-deficient gap was supplemented to achieve the cutting of a very thick workpiece. The simulation results indicated that this method could effectively reduce the machining gap and improve the uniformity of the electric- and flow-field distributions. Experiments verified that when the uninsulated range (machining angle) was reduced from 360° to 90°, the side machining gap was reduced from 462.5 μm to 175 μm. Finally, using optimized machining parameters, array slits with gaps as small as (175±10) μm were machined on a powder superalloy René 88DT sample with a thickness of 10 mm at a feed rate of 16 μm/s. The feasibility of fabricating complex profiles using this method was verified using a self-designed servo device.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00441-5

Key words: Wire electrochemical machining (WECM), Tube electrode, Partial insulation, Machining angle, Electrolyte flushing, Surface quality

Cheng Tang, Zhao Han, Zhong-Qi Zhou, Xiao-Long Fang. Precision wire electrochemical machining of thick structures in powder superalloy René 88DT using a partially insulated tube electrode[J]. Advances in Manufacturing, 2023, 11(4): 618-635.

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[1]	Lorcan O'Toole, Feng-Zhou Fang. Optimal tool design in micro-milling of difficult-to-machine materials[J]. Advances in Manufacturing, 2023, 11(2): 222-247.
[2]	Ben-Kai Li, Qing Miao, Min Li, Xi Zhang, Wen-Feng Ding. An investigation on machined surface quality and tool wear during creep feed grinding of powder metallurgy nickel-based superalloy FGH96 with alumina abrasive wheels[J]. Advances in Manufacturing, 2020, 8(2): 160-176.

Precision wire electrochemical machining of thick structures in powder superalloy René 88DT using a partially insulated tube electrode

Precision wire electrochemical machining of thick structures in powder superalloy René 88DT using a partially insulated tube electrode

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