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<p>Integral shrouded blisks serve as the core components of rocket engines, with semi-closed, twisted, and narrow flow channels, posing challenges for traditional machining methods. Electric discharge machining (EDM) is considered to be a crucial method for machining these parts. However, the complex geometric features make it difficult to remove debris from the inter-electrode gap, which greatly affects the efficiency of EDM. This paper aims to study prefabricated hole sucking method, in which the working liquid is sucked from the opposite side of the flow channel by small holes to promote debris evacuation. High-speed camera observations of debris motion and microscopic observations of debris size lay the foundation for particle tracking simulation. The impact of sucking pressure, pre-hole diameter, number, and length on suction efficiency is explored by simulation and arc-shaped flow channel machining. When the pre-hole pressure is below -10&#xa0;kPa and the diameter is 1.2&#xa0;mm, increasing both parameters significantly enhance suction effect. Additionally, increasing the number of small-diameter pre-holes can significantly enhance the flow velocity and improve the uniformity of the inter-electrode fluid. The experimental results for blisk flow channel machining show that the hole sucking method, compared to flush with tool retraction, leads to a 114.4% increase in overall processing efficiency. Moreover, the enhanced suction effect allows for further optimization of electrical parameters, resulting in a total efficiency increase of 203.5%. Therefore, hole sucking is a suitable method for EDM of integral shrouded blisks.</p>

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Study of hole sucking on debris evacuation and processing efficiency in EDM of integral shrouded blisks

  • 期刊论文

  • 发表日期：

    2025年6月18日

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  • Hongfei Wei,
  • Feng Wang,
  • Jing Zhou,
  • Bowen Shen,
  • Xiaoming Kang

摘要

Integral shrouded blisks serve as the core components of rocket engines, with semi-closed, twisted, and narrow flow channels, posing challenges for traditional machining methods. Electric discharge machining (EDM) is considered to be a crucial method for machining these parts. However, the complex geometric features make it difficult to remove debris from the inter-electrode gap, which greatly affects the efficiency of EDM. This paper aims to study prefabricated hole sucking method, in which the working liquid is sucked from the opposite side of the flow channel by small holes to promote debris evacuation. High-speed camera observations of debris motion and microscopic observations of debris size lay the foundation for particle tracking simulation. The impact of sucking pressure, pre-hole diameter, number, and length on suction efficiency is explored by simulation and arc-shaped flow channel machining. When the pre-hole pressure is below -10 kPa and the diameter is 1.2 mm, increasing both parameters significantly enhance suction effect. Additionally, increasing the number of small-diameter pre-holes can significantly enhance the flow velocity and improve the uniformity of the inter-electrode fluid. The experimental results for blisk flow channel machining show that the hole sucking method, compared to flush with tool retraction, leads to a 114.4% increase in overall processing efficiency. Moreover, the enhanced suction effect allows for further optimization of electrical parameters, resulting in a total efficiency increase of 203.5%. Therefore, hole sucking is a suitable method for EDM of integral shrouded blisks.