RESEARCH PAPERS: Electrical Effects at the Macro and Micro Scale

Multiphysics Simulation of Electrochemical Machining Process for Three-Dimensional Compressor Blade

[+] Author and Article Information
Toshiaki Fujisawa

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

Kazuaki Inaba, Makoto Yamamoto

Department of Mechanical Engineering, Tokyo University of Science, 1-14-6 Kudankita, Chiyoda-ku, Tokyo 102-0073, Japan

Dai Kato

Aero-Engine and Space Operations, Ishikawajima-Harima Heavy Industries Co., Ltd., 229 Tonogaya, Mizuho-machi, Nishitama-gun, Tokyo 190-1297, Japan

J. Fluids Eng 130(8), 081602 (Jul 30, 2008) (8 pages) doi:10.1115/1.2956596 History: Received April 20, 2007; Revised December 10, 2007; Published July 30, 2008

Electrochemical machining (ECM) is an advanced machining technology. It has been applied in highly specialized fields such as aerospace, aeronautics, and medical industries. However, it still has some problems to be overcome. The efficient tool design, electrolyte processing, and disposal of metal hydroxide sludge are the typical issues. To solve such problems, computational fluid dynamics is expected to be a powerful tool in the near future. However, a numerical method that can satisfactorily predict the electrolyte flow has not been established because of the complex nature of flows. In the present study, we developed a multiphysics model and the numerical procedure to predict the ECM process. Our model and numerical procedure satisfactorily simulated a typical ECM process for a two-dimensional flat plate. Next, the ECM process for a three-dimensional compressor blade was simulated. Through visualization of the computational results, including the multiphase flow, and thermal and electric fields between the tool and the blade, it is verified that the present model and numerical procedure could satisfactorily predict the final shape of the blade.

Copyright © 2008 by American Society of Mechanical Engineers
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Figure 1

Schematic of physics in the ECM process

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Figure 2

Schematic of ECM configuration and computational grid for 2D flat plate

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Figure 3

Comparison of predicted gaps for different conditions in 2D flat plate ECM

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Figure 4

Streamwise change of section-averaged flow characteristics

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Figure 5

Schematic of ECM for 3D compressor blade

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Figure 6

Computational grid

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Figure 7

Comparison of predicted blade shapes

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Figure 8

Comparison of errors in each case

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Figure 9

Flow nature around the separation region near the hub

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Figure 10

Flow nature around the tip

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Figure 11

Dissolved volume distributions on the pressure surface

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Figure 12

Contours of velocity and H2 void fraction at different spanwise sections and dissolved volume distribution on blade surface (top: 81% span, middle: 61% span, and bottom: 40% span, at 25th stage)



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