Multi-Physical Field Coupling Simulation and Experiments with Pulse Electrochemical Machining of Large Size TiAl Intermetallic Blade

Large size TiAl alloy blade is one of the important parts to reduce weight advanced aero-engines. However, precision manufacturing such blades a challenge due their large size, low ductility at room temperature, and high hardness alloy. Electrochemical machining (ECM) very promising method for blades, considering its unique advantages. In this study, comprehensive multi-physical field coupling simulation pulse ECM experiments on are carried out. Geometric theoretical models involving electric fields, gas-liquid two-phase flow, heat transfer, anodic dissolution developed. The variation bubble, electrolyte flow rate, electrical conductivity outlet different areas surface with processing time distribution along channel in gap revealed by simulation. It found that influence temperature more dominant than bubble concentration. Finally, out, experimental results analyzed detail. efficiency quality realized. roughness accuracy about Ra 0.9 μm 0.18 mm, respectively.