Procedure of creating three-dimensional solid models of tool electrodes for electrochemical pulse machining of gas turbine engine parts in CAD-systems with their parametric coupling with software module profiling

This work is dedicated to the creation of parametric solid models of tool electrodes based on the results of the calculation of the previously created software module. The developed technique will facilitate the solution of the problem of technological preparation of the operation of electrochemical machining (ECM) of a gas turbine emgine copressor. In this case, the solution could be obtained by simulations in several iterations and would completely preclude all machine work and mechanical hand-operated development of electrodes. The technique is based on a mathematical model of electrochemical shaping of a gas turbine engine airfoil using pulse current. In developing the model the electric comductivity and temperature were taken to be constant, the current output depended only on the current density, the anode and cathode overvoltage was determined by the polarization curves, the peculiarities of the anode process dynamics were considered by the current density and the parameters of the hydrodynamic conditions were taken to be optimal. A software module was developed in the course of developing the procedure. The module developed provides easy implementation of a mathematical model of profiling tool electrodes in ECM.  Electronic models of electrode profiles that could be used in producing control software for machining electrode profiles on CNC machines are the end result of such simulation.