Simulation and experiment research on liquid channel of diffuser blade by electrochemical machining

Aiming to solve the problems of low electrolyte flow rate at leading edge and trailing poor uniformity end clearance field during electrochemical machining (ECM) diffuser blades, a gap simulation model was established by designing three liquid-increasing channels cathode. The results indicate that hole channel (LIHC) with an outlet area S 1.5 mm2 distance L from center point 3.2 mm achieves optimal performance. In addition, experiment show optimized cathode significantly improves efficiency, accuracy, surface quality. Specifically, feed speed increased 0.25 mm/min 0.43 mm/min, taper decreased 4.02° 2.45°, roughness value blade back reduced 1.146 0.802 µm. Moreover, basin 0.961 0.708 µm, hub 0.179 0.119 prove effectiveness proposed method can be used for ECM other complex structures uniformity.