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Stage identification and process optimization for fast drilling EDM of film cooling holes using KBSI method

Advances in Manufacturing 2023年第3期11卷 477-491页

作者： Jian Wang Xue-Cheng Xi Ya-Ou Zhang Fu-Chun Zhao Wan-Sheng Zhao State Key Laboratory of Mechanical System and Vibration Shanghai 200240People's Republic of China School of Mechanical Engineering Shanghai Jiao Tong UniversityShanghai 200240People's Republic of China

Fast drilling electrical discharge machining(EDM)is widely used in the manufacture of film cooling holes of turbine ***,due to the various hole orientations and severe electrode wear,it is relatively intricate to accurately and timely identify the critical moments such as breakout,hole completion in the drilling process,and adjust the machining strategy *** breakout detection and hole completion determination methods are not suitable for the high-efficiency and fully automatic production of film cooling holes,for they almost all depend on preset thresholds or training data and become less appropriate when machining condition *** the breakout and hole completion detection problems can be abstracted to an online stage identification problem,in this paper,a kurtosis-based stage identification(KBSI)method,which uses a novel normalized kurtosis to denote the recent changing trends of gap voltage signals,is developed for online stage *** identification accuracy and generalization ability of the KBSI method have been verified in various machining *** improve the overall machining efficiency,the influence of servo control parameters on machining efficiency of each machining stage was analyzed experimentally,and a new stage-wise adaptive control strategy was then proposed to dynamically adjust the servo control parameters according to the online identification *** performance of the new strategy is evaluated by drilling film cooling holes at different hole *** results show that with the new control strategy,machining efficiency and the machining quality can be significantly improved.

关键词： Fast drilling electrical discharge machining(EDM) film cooling holes Breakout detection Hole completion determination Stage identification Process optimization

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Breakthrough detection in electrochemical discharge drilling to enhance machining stability

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Chinese Journal of Aeronautics 2023年第6期36卷 460-475页

作者： Tianyu GENG Zhengyang XU Chenxiang ZHANG Jin NING College of Mechanical&Electrical Engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China

film cooling holes are widely used in aero-engine turbine *** blades feature large numbers of holes with complex angles and require a high level of surface *** discharge drilling(ECDD)combines the high efficiency of electrical discharge drilling(EDD)with high quality of electrochemical drilling(ECD).However,due to the existence of a variety of energy for material removal,accurate and timely detection of breakthroughs is fraught with *** insufficient preset setting distance results in a tiny exit aperture,influencing the structure's *** addition,the electrode is prone to bending at a large overfeeding distance,causing secondary discharge damaging sidewall surface *** paper compares and analyzes the characteristics of processing waveforms using EDD and ECDD.A novel breakthrough detection method is proposed based on the variance signal of average voltage(VSAV)to increase machining stability and achieve fabrication without a recast *** method extracts the fluctuation transformation by calculating the variance of the *** signal detection,the overfeeding distance is *** experiment is used to validate the breakthrough detection with 100%accuracy in all *** optimum overfeeding distances for hole angles of 0°,30°,and 60° are obtained,and the stable removal of the recast layer is ***,the effectiveness of the method is verified on a typical workpiece with a double-wall structure and a nickel-based single crystal blade.

关键词： Change detection Electrochemical discharge drilling(ECDD) Electric discharge film cooling holes Recast layer Variance signal of average voltage(VSAV)

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