Research on shaping law in electrochemical machining for the leading/trailing edge of the blade

  • Dong ZhuEmail author
  • Lingguo Yu
  • Jibin Zhao
  • Jia Liu
  • Zhengyang Xu


The blade is a crucial component in an aero engine. In electrochemical machining of blades, the shaping law of the leading/trailing edge is intricate because of the complexity of the flow field and electric field distributions at these locations. This paper researches the formation of the leading/trailing edge. The dissolution process of the leading/trailing edge is simulated using an initial cathode and then its forecasted profile is obtained. The cathode is then adjusted according to the deviations between the forecasted profile and the model. Meanwhile, a coefficient between the deviations and the corrected value of the cathode is obtained after optimization simulation and the optimal value is about 1.17. Then, an optimal cathode is acquired by using the optimal coefficient. In addition, the effects of the thermal and hydrogen generation are also considered. The temperature increases to 8.28 K and the bubble rate increases to 25.30% at the electrolyte outlet. Furthermore, verification experiments are performed with the optimal cathode. The results show that the margin edges are formed and the accuracy is 0.13 mm of the leading edge, while the allowance of the profile at the electrolyte outlet is larger than that at the inlet, which means that the bubble rate is dominant in the inter-electrode gap. The results indicate that the design method for the leading/trailing edge is appropriate and can be used for manufacturing other complex components such as blisks and diffusers.


Electrochemical machining Blade Trailing edge Leading edge Simulation 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


Funding information

This work is financially supported by the National Nature Science Foundation of China (51675271), the Jiangsu Science Fund for Distinguished Young Scholars (BK20170031), the Fundamental Research Funds for the Central Universities (NE2014104 and NE 2017003).


  1. 1.
    Li ZY, Niu ZW (2007) Convergence analysis of the numerical solution for cathode design of aero-engine blades in electrochemical machining. Chin J Aeronaut 20(6):570–576CrossRefGoogle Scholar
  2. 2.
    Fujisawa T, Inaba K, Yamamoto M, Kato D (2008) Multiphysics simulation of electrochemical machining process for three-dimensional compressor blade. J Fluids Eng 130(8):081602-1-8CrossRefGoogle Scholar
  3. 3.
    Paczkowski T, Sawicki J (2008) Electrochemical machining of curvilinear surfaces. Mach Sci Technol 12(1):33–52CrossRefGoogle Scholar
  4. 4.
    Tsuboi R, Yamamoto M (2010) Modeling and applications of electrochemical machining process. ASME Int Mech Eng Congr Expo 4:377–384Google Scholar
  5. 5.
    Zhu D, Zhu D, Xu ZY, Xu Q, Liu J (2010) Investigation on the flow field of W-shape electrolyte flow mode in electrochemical machining. J Appl Electrochem 40(3):525–532CrossRefGoogle Scholar
  6. 6.
    Zhu D, Zhu D, Xu ZY, Zhou LS (2013) Trajectory control strategy of cathodes in blisk electrochemical machining. Chin J Aeronaut 26(4):1064–1070CrossRefGoogle Scholar
  7. 7.
    Klocke F, Zeis M, Klink A, Veselovac D (2013) Experimental research on the electrochemical machining of modern titanium- and nickel-based alloys for aero engine components. Procedia CIRP 6:368–372CrossRefGoogle Scholar
  8. 8.
    Klocke F, Zeis M, Klink A, Veselovac D (2013) Technological and economical comparison of roughing strategies via milling, sinking-EDM, wire-EDM and ECM for titanium- and nickel-based blisks. CIRP J Manuf Sci Technol 6(3):198–203CrossRefGoogle Scholar
  9. 9.
    Klocke F, Zeis M, Klink A (2015) Interdisciplinary modelling of the electrochemical machining process for engine blades. CIRP Ann Manuf Technol 64(1):217–220CrossRefGoogle Scholar
  10. 10.
    Klocke F, Zeis M, Harst S, Klink A, Veselovac D, Baumgärtner M (2013) Modeling and simulation of the electrochemical machining (ECM) material removal process for the manufacture of aero engine components. Procedia CIRP 8:265–270CrossRefGoogle Scholar
  11. 11.
    Li ZY, Niu ZW, Li L (2013) Parameters optimization and experimental study of aero-engine blade in electrochemical machining based on high-risk machining parameter elimination. Key Eng Mater 567:67–72CrossRefGoogle Scholar
  12. 12.
    Kozak J (2013) The computer simulation of electrochemical shaping processes. IAENG Trans Eng Tech, Lect Notes Elec Eng 170:95–107CrossRefGoogle Scholar
  13. 13.
    Tang L, Zhu QL, Zhao JS, Fan ZJ (2017) Research on the cathode design and experiments of electrochemical machining a closed impeller internal flow channel. Int J Adv Manuf Technol 88(9–12):2517–2525CrossRefGoogle Scholar
  14. 14.
    Sohrabpoor H, Khanghah SP, Shahraki S, Teimouri R (2016) Multi-objective optimization of electrochemical machining process. Int J Adv Manuf Technol 82(9–12):1683–1692CrossRefGoogle Scholar
  15. 15.
    Qu NS, Xu ZY (2013) Improving machining accuracy of electrochemical machining blade by optimization of cathode feeding directions. Int J Adv Manuf Technol 68(5–8):1565–1572CrossRefGoogle Scholar
  16. 16.
    McGeough JA (1974) Principle of electrochemical machining. Chapman & Hall, LondonGoogle Scholar
  17. 17.
    Collett DE, Hewson-Browne RC, Windle DW (1970) A complex variable approach to electrochemical machining problems. J Eng Math 4(1):29–37CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Dong Zhu
    • 1
    Email author
  • Lingguo Yu
    • 1
  • Jibin Zhao
    • 1
  • Jia Liu
    • 1
  • Zhengyang Xu
    • 1
  1. 1.National Key Laboratory of Science and Technology on Helicopter TransmissionNanjing University of Aeronautics & AstronauticsNanjingChina

Personalised recommendations