Investigation of leveling ability improvement in pulse electrochemical machining for aero structural components

摘要

In electrochemical machining of aero structural components, the allowance distribution between the blank and the model is generally not uniform, which may influence the final precision of components. However, proper leveling can reduce the negative impacts of this nonuniformity and enhance machining accuracy. This paper proposes a mathematical model for pulse electrochemical machining (ECM) to simulate the corrosion process in order to improve the leveling. Several machining parameters, such as power voltage, pulse duty, and frequency, are considered to optimize the leveling ratio. The optimal parameters are obtained from the simulation. The simulation results show that the leveling ratio improves with the decrease of pulse duty and voltage and the increase of frequency. Furthermore, the pulse duty has a more significant effect on the leveling ability than the voltage and the frequency. In addition, verified experiments are carried out and the results are consistent with the simulation. It indicates that the proposed model is effective and can be used for complex structural components in ECM.