Fabrication of Small Hole Based on EDM & ECM Hybrid Machining Method

XU Zhengyang; ZHANG Chenxiang

doi:10.16080/j.issn1671-833x.2018.03.016

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Fabrication of Small Hole Based on EDM & ECM Hybrid Machining Method

更新时间：2025-10-30

- Fabrication of Small Hole Based on EDM & ECM Hybrid Machining Method
- Aeronautical Manufacturing Technology Vol. 61, Issue 3, Pages: 16-22(2018)
- 作者机构：
  
  南京航空航天大学机电学院,南京,210016
- 作者简介：
- 基金信息：
- DOI：10.16080/j.issn1671-833x.2018.03.016
  CLC：
- Published：2018
- 稿件说明：
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徐正扬，张辰翔. 基于电火花-电解复合加工方法的微小孔制造[J]. 航空制造技术, 2018, 61(3): 16-22.

XU Zhengyang, ZHANG Chenxiang. Fabrication of Small Hole Based on EDM & ECM Hybrid Machining Method[J]. Aeronautical Manufacturing Technology, 2018, 61(3): 16-22.
徐正扬，张辰翔. 基于电火花-电解复合加工方法的微小孔制造[J]. 航空制造技术, 2018, 61(3): 16-22. DOI： 10.16080/j.issn1671-833x.2018.03.016.

XU Zhengyang, ZHANG Chenxiang. Fabrication of Small Hole Based on EDM & ECM Hybrid Machining Method[J]. Aeronautical Manufacturing Technology, 2018, 61(3): 16-22. DOI： 10.16080/j.issn1671-833x.2018.03.016.

摘要

航空发动机涡轮叶片气膜冷却孔的制造一直是难点所在。提出了微小孔电火花- 电解同步复合加工方法，通过电火花加工和电化学溶解同步进行，实现小孔的高效无重铸层制造。针对电火花- 电解复合加工方法进行了试验研究，观测了复合加工过程中的试验现象，研究了加工过程中的电压电流波形和加工产物成分，计算了电化学溶解作用占复合加工材料去除量的比例，分析了工作液电导率对电极损耗的影响，比较了复合加工与纯电火花加工后的微小孔加工质量。试验结果表明，电火花- 电解复合加工可以在微小孔制造完成的同时，有效去除孔壁上的重铸层。提出的方法可以为实现航空发动机涡轮叶片气膜冷却孔的高效无重铸层制造提供新的解决途径，并可用于其他微小群孔类零部件的加工。

Abstract

The fabrication of film cooling holes on turbine blade of aero-engine is always a difficult problem. In this paper

the EDM ECM hybrid machining method for small holes drilling is presented

in which electrical discharge machining (EDM) and electrochemical machining (ECM) occur simultaneously. According to experimental studies on the EDM ECM hybrid machining method

machining process phenomenon

waveforms of voltage and current were observed. The composition of processed product was analyzed

and the ratio of material removal by electrochemical dissolution was also calculated. Effects of different working fluid conductivities on tool electrode wear performances were studied. Machining qualities of small holes by hybrid machining and pure EDM were compared. The results of experiments indicate that the EDM ECM hybrid machining can effectively remove the recast layers on the side wall of the hole in the machining process. Thus

a novel way to machining the film cooling holes can be provided with high efficiency and free of recast layer. It also can be used for machining other small hole structures in aero-engine.

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