航空发动机微小群孔结构低温环境放电-电解复合加工方法

航空发动机关键部件中存在大量群孔结构，其孔径小、材料难加工、表面质量和加工效率要求高，制造十分困难。本项目聚焦于难加工材料关键部件的微小孔制造难题，提出低温环境放电-电解高表面完整性复合加工方法。深入分析低温环境下放电-电解复合加工过程，阐明低温环境放电-电解复合加工的多场耦合作用机理，低温条件下的电化学溶解特性等基础科学问题，建立低温环境放电-电解复合加工的理论基础。同时突破溶液流场设计及优化、重铸层强化溶解方法、低温环境下复合加工的参数匹配等关键技术，形成低温环境放电-电解同步复合加工方法的理论和技术体系，充分释放出该方法在航空发动机高表面完整性加工领域的潜力。本项目研究工作具有鲜明的创新性，处于特种加工的前沿探索，也密切结合国家重大需求和工程实际，符合重大研究计划的指南要求。研究将获得具有自主知识产权的原创性成果，提升航空发动机难加工材料关键部件的微小孔结构制造水平。

There are a large number of small and micro holes structures on key parts in aero engine. It is very difficult to machine the holes because of small diameters, difficult-to-cut materials and high requirements of surface quality and machining efficiency. This project focuses on the machining challenge of small and micro holes on the critical components of aero engines such as film cooling holes on turbine blades. A new synchronous hybrid machining method of EDM - ECM in cryogenic environment for small and micro holes with high surface integrity is presented in the project. The EDM and ECM process in cryogenic environment will be analyzed. The basic scientific questions, such as multi - field coupling mechanism of electrical discharge - electrochemical hybrid machining in cryogenic environment, electrochemical dissolution characteristics under low temperature, will be clarified. The key technologies such as flow field design and optimization of solution, the remove method of recast layer, and the optimization of parameters in hybrid method under low temperature will be made breakthroughs in the project. The theory and technology system of EDM – ECM hybrid machining method in cryogenic environment will be established for releasing the potential of this method in the high surface integrity manufacturing of micro and small holes in aero engine. The research work of this project is innovative and focuses on the frontier exploration of non-traditional machining technologies, as well as combines with the significant demand of the state and engineering practice. The contents of research accord with the guide requirements of the major research plan. The original results with independent intellectual property rights can be achieved by this project. The manufacturing level of small and micro holes on the critical components with difficult to machine materials of aero engines could be enhanced.