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APPLICATION OF MULTI-PHYSICS MODELING IN ELECTRO-CHEMICAL MACHINING PROCESS FOR 3D COMPRESSOR BLADE

DOI: 10.1615/ICHMT.2008.CHT.1950
page 14

Ryo Tsuboi
Graduated School of Mechanical Engineering, Tokyo University of Science 1-14-6, Kudankita, Chiyoda-ku, Tokyo, 102-0073, Japan

Makoto Yamamoto
Department of Mechanical Engineering, Tokyo University of Science, 6-3-1 Niijuku, Katsushika-ku, Tokyo, 125-8585, Japan

Dai Kato
Aero Engine & Space Operations, Ishikawajima-Harima Heavy Industries Co., Ltd. 229, Tonogaya, Nishitamagun, Tokyo, 190-1297, Japan

Sinopsis

Electro-Chemical Machining (ECM) is an advanced machining technology and has been applied to highly specialized fields, such as aerospace, aeronautics, and medical industries. However, some problems remain to be solved. The efficient tool-design, electrolyte processing, and disposal of metal hydroxide sludge are typical problems. To solve such problems, CFD is thought to have potential as a powerful tool. However, a numerical method that can satisfactorily predict the ECM process has not been established because of the complex flow natures.
In a previous study, we presented a new model to calculate the flow fields in an ECM process. This model is based on a two-way coupling method, taking the interaction between gas and liquid phases into account. In this coupling method, we assumed that electrolyte and generated hydrogen bubbles over a cathode surface have the same velocity. Therefore, we could simplify the governing equations. Since the flow field had a non-uniform density distribution due to hydrogen bubbles, a low Mach number approximation was applied to solve the pressure Poisson equation.
In the present study, we first simulate an ECM process for a flat plate channel configuration. Based on this simulation, we obtain some appropriate parameters, such as the diffusion coefficient for gas phase and the diameter of the hydrogen bubble, by comparing the numerical result with the experimental data. Second, we applied the developed model to the simulation of an ECM process for a 3D compressor blade configuration. Comparing the numerical results with the experimental data, we investigate the final shape of the dissolved blade and verify the present model.

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