A novel method for in-situ successive electrochemical machining of blisk using a three-layer electrode with partitioned conductive mode

Electrochemical machining is employed in blisk manufacturing due to its advantages. To simplify processing steps and shorten the production cycle, this study proposes a in-situ successive ECM method using a three-layer electrode with a partitioned conduction mode to integrated rough-finish blisk machining in three successive steps. In this study, the single-layer electrode side conductive (SESC) and insulation (SESI) are compared with the three-layer electrode partitioned conductive (TEPC). The channel forming process is simulated, and the results indicate that compared with SESC, the channel contour machined with TEPC has no taper. Compared with SESI, the three-layer electrode enables successive and partitioned conductive machining of blade profiles. Experimental results confirm that TEPC reduced surface roughness of concave and convex profiles by 46% and 26.8%, and diminished allowance differences by 85% and 92.5%, respectively, compared to SESC. These outcomes validate the feasibility of IS-SECM and the effectiveness of TEPC mode.