High Efficient Electrical Discharge Machining Nickel-based Closed Integral Impeller with Gropes of Electrodes

doi:10.3901/JME.2025.05.364

Abstract

Abstract: To address the challenges associated with poor surface quality and low efficiency in machining nickel-based superalloy closed integral impellers, a method of multi-electrode EDM process planning based on a multivariate adaptive control system is proposed. The machining process is categorized into rough and finish machining stages. During rough machining, a multivariate adaptive control system is established to dynamically adjust the gap voltage, pulse interval, and discharge time in real-time, ensuring machining stability. Concurrently，the influence of pulse width on the machining state is scrutinized to determine the optimal roughing process conditions. Furthermore，the effects of polarity effect, current size, and machining allowance on surface quality are examined to derive the optimal finishing conditions. Experimental findings demonstrate that the proposed process method enhances processing efficiency and diminishes impeller surface roughness. Ultimately, the machined blade's surface roughness measures Ra1.2-1.5 µm, surpassing the Ra3.2 µm requirements of aviation enterprises, with processing efficiency doubling. The process method exhibits promising application prospects in machining complex parts characterized by difficulty and significant distortion.

Key words: grouped electrode EDM, closed integral impeller, multi-electrode adaptive control, nickel-based superalloy, process planning

CLC Number:

TG661

ZHAO Meng, ZHOU Ming, HU Tianshang, YANG Jianwei, WANG Yianxue, WANG Liang, XU Pei, XIN Fangqing. High Efficient Electrical Discharge Machining Nickel-based Closed Integral Impeller with Gropes of Electrodes[J]. Journal of Mechanical Engineering, 2025, 61(5): 364-374.

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http://www.cjmenet.com.cn/EN/Y2025/V61/I5/364

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