Parameter Optimization and Experimental Study on Tool-Vibration-Assisted Pulsed Electrochemical Machining of γ-TiAl TNM Blades

Electrochemical machining (ECM) is one of the main methods for manufacturing gamma-titanium aluminum (γ-TiAl) alloy blades of new-type aero-engines. Tool-vibration-assisted pulsed electrochemical machining (VPECM) is an important method to improve the manufacturing accuracy. In order to determine the influence of processing parameters on the VPECM quality of γ-TiAl TNM alloys, multi-field simulations with different parameter combinations of peak voltage, feed rate, duty cycle, and tool vibration frequency were carried out. The influence of bubble rate and temperature increase on the conductivity distribution in the machining gap under different parameter combinations was analyzed. Then, orthogonal experiments with the above four processing parameters were carried out. The experimental results of surface roughness, replication accuracy, and average current density in the pulse width were interpreted by a grey relational analysis, and the best parameter combination was determined. Finally, four blade-shaped γ-TiAl TNM alloy specimens were processed by using the optimized parameter combination, which had good replication accuracy and surface quality.