Abstract There are many large-scale revolving parts in aerospace engines, which usually require relatively large machining allowances to ensure production of the necessary shapes and sizes. Efficient removal of the machining allowances from such large-scale revolving parts, especially for hard-to-cut materials, represents a challenge for traditional mechanical processing. In this research, electrochemical turning with a universal cylindrical electrode is proposed as an efficient method to remove the large machining allowance of revolving parts. Lateral flow and internal flow patterns are exploited to ensure timely removal of electrolysis products and Joule heat. The electric field distribution shows that the current in the machining area increases significantly for the method. The flow field distribution shows that a more uniform flow velocity distribution can be obtained using an internal flow pattern. Experiments were performed to verify the proposed method. The results show that the internal flow pattern allows for faster feed rates and more stable processing, and the material removal rate may be improved significantly through use of an optimized flow pattern, especially for work-pieces with a large machining allowance. To demonstrate application, three differently shaped revolving structures were machined successfully with a radial removal allowance of 10 mm.

中文翻译：

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使用通用圆柱电极对旋转零件进行大余量电化学车削

摘要 航空发动机中的大型回转件很多，通常需要较大的加工余量才能保证生产出所需的形状和尺寸。有效去除此类大型旋转零件的加工余量，尤其是对于难切削材料，是对传统机械加工的挑战。在这项研究中，提出了使用通用圆柱电极的电化学车削作为去除旋转零件大加工余量的有效方法。利用横向流动和内部流动模式确保及时去除电解产物和焦耳热。电场分布表明，该方法加工区域的电流显着增加。流场分布表明，使用内部流型可以获得更均匀的流速分布。进行了实验以验证所提出的方法。结果表明，内部流型允许更快的进给速度和更稳定的加工，并且通过使用优化的流型可以显着提高材料去除率，特别是对于加工余量大的工件。为了演示应用，成功加工了三个不同形状的旋转结构，径向去除余量为 10 毫米。通过使用优化的流型可以显着提高材料去除率，特别是对于加工余量大的工件。为了演示应用，成功加工了三个不同形状的旋转结构，径向去除余量为 10 毫米。通过使用优化的流型可以显着提高材料去除率，特别是对于加工余量大的工件。为了演示应用，成功加工了三个不同形状的旋转结构，径向去除余量为 10 毫米。