Developing additive technology of tool electrode manufacturing for aircraft engines parts machining

Аuthors

Dyul'dina N. E.^*, Nekhoroshev M. V.^**, Pronichev N. D.^***

Samara National Research University named after Academician S.P. Korolev, 34, Moskovskoye shosse, Samara, 443086, Russia

*e-mail: spanchbobik04@mail.ru
**e-mail: maxnogood@gmail.com
***e-mail: pdla@ssau.ru

Abstract

The paper offers new technological solutions for gas turbine engines (GTE) manufacturing. These solutions are based on special processing methods using and additive technology implementation. To improve technological process of GTE parts manufacturing the authors suggest new technology of polymeric tool electrode (TE) fabrication with subsequent metal coating of its work surface using electrodeposition method. The most complex problem consists in ensuring accuracy of the profiled surface in the process of electrodeposition of a metal layer.

The objective of the work is developing computer model of the process of electrodeposition of metal on a dielectric TE for electrochemical machining (ECM).

This presented method consists in creating the information model, and studying the main process parameters of electrochemical deposition: electrolyte and electrode surface potentials, electrode reaction behavior, thickness and uniformity of the coating. While analytic model development parameters of electrode reaction, such as the exchange current density; electrochemical anodic and cathodic transfer coefficients; system electrode reaction equilibrium potential were determined. Besides, the above-mentioned method includes comparison of the formed profile with theoretical one.

The developed information model demonstrates that the metal coating possesses a variable thickness. On the boundary of cathode with electrode junction a thickening, stipulated by electrochemical processes, was formed. Here, in this zone the thickness deviation of the formed profile from a theoretical one is 355 µm. This implies that a minor mechanical processing is needed.

The developed technology allows carry out technological regimes and using the ECM obtain more detailed information on surface shaping.

Keywords:

dielectric electrode for electrochemical machining, conductive coating electrodeposition on polymer electrode, working surface

References

1. Okorokova N.S., Pushkin K.V., Sevruk S.D., Farmakovskaya A.A. Vestnik Moskovskogo aviatsionnogo instituta, 2012, vol. 19, no. 5, pp. 65-71.

2. Kravchenko L.L., Okorokova N.S., Pushkin K.V., Sevruk S.D., Farmakovskaya A.A. Vestnik Moskovskogo aviatsionnogo instituta, 2011, vol. 18, no. 3, pp. 74-81.

3. Zhuk A.Z., Ilyukhin A.S., Okorokova N.S., Sevruk S.D., Farmakovskaya A.A. Vestnik Moskovskogo aviatsionnogo instituta, 2013, vol. 20, no. 2, pp. 198-208.

4. Nekhoroshev M.V., Pronichev N.D., Smirnov G.V. Vestnik Samarskogo universiteta. Aerokosmicheskaya tekhnika, tekhnologii i mashinostroenie, 2015, vol. 14, no. 3-2, pp. 418-424.

5. Nekhoroshev M.V., Pronichev N.D., Smirnov G.V. Vestnik Samarskogo universiteta. Aerokosmicheskaya tekhnika, tekhnologii i mashinostroenie, 2014, no. 5-3(47), pp. 158-166.

6. Nekhoroshev M.V., Pronichev N.D., Smirnov G.V. Computer Simulation of High-Speed Anodic Dissolution Processes of Geometrically-Complex Surfaces of GTE Details. Computer Simulation of High-Speed Anodic Dissolution Processes of Geometrically-Complex Surfaces of GTE Details. The Open Mechanical Engineering Journal, 2014, no. 8, pp. 436-440.

7. Vetter K.J. Electrochemical Kinetics: Theoretical and Experimental Aspects. New York, Academic Press Inc., U.S., 1961, 789 p.