刘为东¹, 罗震^1,2, 敖三三¹, 李洋¹, 刘祖明¹, 张辉¹
AuthorsHTML:刘为东¹, 罗震^1,2, 敖三三¹, 李洋¹, 刘祖明¹, 张辉¹
AuthorsListE:Liu Weidong¹, Luo Zhen^1,2, Ao Sansan¹, Li Yang¹, Liu Zuming¹, Zhang Hui¹
AuthorsHTMLE:Liu Weidong¹, Luo Zhen^1,2, Ao Sansan¹, Li Yang¹, Liu Zuming¹, Zhang Hui¹
Unit:1. 天津大学材料科学与工程学院，天津 300072；2. 高新船舶与深海开发装备协同创新中心，上海 200240
Unit_EngLish:1. School of Materials Science and Engineering, Tianjin University, Tianjin 300072, China
2. Collaborative Innovation Center of Advanced Ship and Deep-Sea Exploration, Shanghai 200240, China
Abstract_Chinese:针对涡轮叶片修复工艺链, 电解加工是一种潜在的后续修形技术．为提高电解修形精度, 对TC4钛合金涡轮叶片叶尖堆焊修复层的电解修形工艺进行了研究．通过建立电场模型, 对工件表面电流密度分布进行了数值计算, 研究阳极形状演化规律, 并以此分析传统阴极工艺的缺陷形成机理．基于仿真结果, 提出了改进阴极以消除过切缺陷, 并建立试验系统, 对堆焊修复后的TC4钛合金叶片进行电解修形的重复试验．结果表明：采用改进阴极, 单组叶片修形时间80 s, 修形后的叶片精度较高, 表面粗糙度R_a
0.8 μm, 具有较好的重复性．
Abstract_English:For turbine blade repairing process chain，electrochemical machining (ECM) is a potential post-machining technology. To improve the machining accuracy，ECM post-machining of overlay welded TC4 turbine blade tips was investigated. By developing the computational model of electrical field，the current density distribution was numerically calculated to obtain the anode shape evolution. The formation principle of overcut phenomena was analyzed according to the calculation. Based on the simulation，a tool correction was proposed to eliminate the overcut，which was verified through repeated experiments arranged on a home-built ECM post-machining system. The results show that the machining time for ECM post-machining single blade with corrected tool is 80 s and the machining accuracy is relatively high. Additionally，good repeatability can be achieved in corrected tool operation and the machined surface roughness is less than 0.8 μm.
Keyword_Chinese:涡轮叶片; 堆焊修复; 电解加工; 数值计算; 改进阴极
Keywords_English:turbine blade; overlay welding repairing; electrochemical machining; numerical calculation; corrected tool

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