Electrochemical grinding of honeycomb seals using sodium dodecylbenzene sulfonate as an eco-friendly inhibitor: machining principle and performance evaluation

doi:10.1007/s40436-024-00531-y

Advances in Manufacturing ›› 2025, Vol. 13 ›› Issue (1): 229-244.doi: 10.1007/s40436-024-00531-y

• • 上一篇

Electrochemical grinding of honeycomb seals using sodium dodecylbenzene sulfonate as an eco-friendly inhibitor: machining principle and performance evaluation

Jin-Hao Wang, Lu Wang, Han-Song Li, Ning-Song Qu

College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, People's Republic of China

收稿日期:2023-12-18 修回日期:2024-02-27 发布日期:2025-02-26
通讯作者: Ning-Song QU,E-mail:nsqu@nuaa.edu.cn E-mail:nsqu@nuaa.edu.cn
作者简介:Jin-Hao Wang is a doctoral candidate of Mechanical Engineering at Nanjing University of Aeronautics and Astronautics, Nanjing, China. His current research interest is electrochemical grinding of difficult-to-cut aerospace materials and thinwalled structures.
Lu Wang is a doctoral candidate of Mechanical Engineering at Nanjing University of Aeronautics and Astronautics, Nanjing, China. His current research interests are electrochemical discharge machining and electrochemical grinding of thin-walled structures.
Han-Song Li is a professor at the College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, China. He has led and participated in numerous national and provincial projects. He has been consistently engaged in research on electrochemical machining technology, focusing entirely on the development of efficient and precision electrochemical machining techniques for difficult-to-cut materials in the aerospace industry. His current research interests include electrochemical machining and complex structure electrochemical grinding.
Ning-Song Qu is a professor at the College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, China. He has led key projects supported by the National High-tech R&D Program and the National Natural Science Foundation of China. He has been engaged in research on non-traditional machining and is a renowned expert in the field of mechanical manufacturing in China. His research achievements bear considerable scientific significance and hold substantial practical value in engineering, with crucial applications in the aerospace industry. His current research interests include electrochemical milling, electrochemical grinding and electrochemical discharge machining.
基金资助:
This study was supported by the Defense Industrial Technology Development Program (Grant No. JCKY2021605B003).

Electrochemical grinding of honeycomb seals using sodium dodecylbenzene sulfonate as an eco-friendly inhibitor: machining principle and performance evaluation

Jin-Hao Wang, Lu Wang, Han-Song Li, Ning-Song Qu

College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, People's Republic of China

Received:2023-12-18 Revised:2024-02-27 Published:2025-02-26
Contact: Ning-Song QU,E-mail:nsqu@nuaa.edu.cn E-mail:nsqu@nuaa.edu.cn
Supported by:
This study was supported by the Defense Industrial Technology Development Program (Grant No. JCKY2021605B003).

摘要/Abstract

摘要： To enhance the performance of aero-engines, honeycomb seals are commonly used between the stator and rotor to reduce leakage and improve mechanical efficiency. Because of the thin-walled and densely distributed honeycomb holes, machining defects are prone to occur during manufacturing. Electrochemical grinding (ECG) can minimize machining deformation because it is a hybrid process involving electrochemical dissolution and mechanical grinding. However, electrolysis will generate excessive corrosion on the honeycomb surface, which affects the sealing capability and operational performance. In this study, an ECG method using an electrolyte of 10% (mass fraction) NaCl is proposed to machine the inner cylindrical surface of the honeycomb seal, and an eco-friendly inhibitor, sodium dodecylbenzene sulfonate (SDBS), is introduced to the electrolyte to inhibit corrosion of the honeycomb structure. A theoretical relationship between the voltage and feed rate during ECG is proposed, and the excessive corrosion of the honeycomb single-foiled segment is used as a measurement of the impact of electrolysis. The corrosion inhibition efficiency of SDBS on the honeycomb material in 10% (mass fraction) NaCl solution is evaluated through electrochemical tests, and the suitable feed rate and optimal concentration of SDBS are determined through ECG experiments. Additionally, the corrosion inhibition effect of SDBS is validated through four groups of comparative experiments. The results indicate that the inhibition efficiency of SDBS increases with increasing concentration, reaching the maximum of 73.44%. The optimal SDBS mass fraction is determined to be 0.06%. The comparative experiments show that excessive corrosion is reduced by more than 40%. This establishes ECG as an effective and environmentally friendly processing method for honeycomb seals by incorporating SDBS into a 10% (mass fraction) NaCl solution.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00531-y

关键词: Electrochemical grinding (ECG), Honeycomb seal, Sodium dodecylbenzene sulfonate (SDBS), Eco-friendly inhibitor

Abstract: To enhance the performance of aero-engines, honeycomb seals are commonly used between the stator and rotor to reduce leakage and improve mechanical efficiency. Because of the thin-walled and densely distributed honeycomb holes, machining defects are prone to occur during manufacturing. Electrochemical grinding (ECG) can minimize machining deformation because it is a hybrid process involving electrochemical dissolution and mechanical grinding. However, electrolysis will generate excessive corrosion on the honeycomb surface, which affects the sealing capability and operational performance. In this study, an ECG method using an electrolyte of 10% (mass fraction) NaCl is proposed to machine the inner cylindrical surface of the honeycomb seal, and an eco-friendly inhibitor, sodium dodecylbenzene sulfonate (SDBS), is introduced to the electrolyte to inhibit corrosion of the honeycomb structure. A theoretical relationship between the voltage and feed rate during ECG is proposed, and the excessive corrosion of the honeycomb single-foiled segment is used as a measurement of the impact of electrolysis. The corrosion inhibition efficiency of SDBS on the honeycomb material in 10% (mass fraction) NaCl solution is evaluated through electrochemical tests, and the suitable feed rate and optimal concentration of SDBS are determined through ECG experiments. Additionally, the corrosion inhibition effect of SDBS is validated through four groups of comparative experiments. The results indicate that the inhibition efficiency of SDBS increases with increasing concentration, reaching the maximum of 73.44%. The optimal SDBS mass fraction is determined to be 0.06%. The comparative experiments show that excessive corrosion is reduced by more than 40%. This establishes ECG as an effective and environmentally friendly processing method for honeycomb seals by incorporating SDBS into a 10% (mass fraction) NaCl solution.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00531-y

Key words: Electrochemical grinding (ECG), Honeycomb seal, Sodium dodecylbenzene sulfonate (SDBS), Eco-friendly inhibitor

Jin-Hao Wang, Lu Wang, Han-Song Li, Ning-Song Qu. Electrochemical grinding of honeycomb seals using sodium dodecylbenzene sulfonate as an eco-friendly inhibitor: machining principle and performance evaluation[J]. Advances in Manufacturing, 2025, 13(1): 229-244.

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Electrochemical grinding of honeycomb seals using sodium dodecylbenzene sulfonate as an eco-friendly inhibitor: machining principle and performance evaluation

Electrochemical grinding of honeycomb seals using sodium dodecylbenzene sulfonate as an eco-friendly inhibitor: machining principle and performance evaluation

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