Investigation of electrolyte pressure effect on blisk blades during electrochemical machining

Materials with high mechanical properties such as titanium, nickel and super alloys are generally preferred in the manufacture of Blisk blades. Electrochemical processing method is usually preferred in blisk production due to their complex geometry and the difficulty of manufacturing of them with desired materials. However, the use of high electrolyte pressure in electrochemical applications causes problems in structures with thin geometry such as blisk blade. In this thesis; deformation of turbine blades produced by electrochemical processing due to high electrolyte pressure during production was analyzed. The natural vibration analysis of the blades was also studied. The pressure distribution created by the electrolyte on the blade surface was obtained in the fluent environment and transferred to the static structural environment where the deformation analysis was carried out. In the analyzes, 3 different parameters were examined, namely blade thickness, blade material and pump pressure. With these parameters, 270 deformation values were obtained. The obtained deformation values were compared with the gap distances between the cathode and the anode. Thus, the appropriate pressure values for the electrolyte to be used in the production of blisk blades was determined numerically. In the study, the highest deformation values were taken as reference. These values were found on the blade in the region that is the furthest from the fixed surface and the most curved area. In addition, it has been determined that high pressure conditions are not suitable for 0.5 mm gap distance.