Abstract: Electrochemical machining (ECM) is used as one of the main technologies to produce blisk. The uniformity of the angles between feeding and workpiece surface normal directions is a critical factor to affect the ECM process accuracy. In order to improve the ECM accuracy of turbine blisk, the method to optimize the feeding direction in ECM is studied. Gaps between the cathodes and anode are influenced by the uniformity of angles which between feeding and workpiece surface normal directions. On the base of analyzing the disadvantage of traditional feeding direction, a new method to optimize the feeding direction of ECM blisk is presented. The optimization method is based on the evaluation parameter which refers to the maximum angle between feeding and workpiece surface normal direction. The optimization method is to minimize the evaluation parameter. In order to verify the validity of the optimization method, the optimization of feeding direction design in ECM blisk is carried. The rational feeding direction is obtained by using the golden section method. The experimental investigations are carried out to evaluate the rationality of the feeding direction. The results reveal that the accuracy of blisk is enhanced with this optimal feed direction.

Key words: electrochemical machining;blisk;feeding;optimization, CIET specimen, crack front constraint effect, J-Q-M theory, normalization method, Ductile fracture behaviour