The conductive shaft structure based on symmetrical copper bar scheme is determined. By establishing the thermoelectric coupling model of the conductive shaft, the distribution law of temperature field and thermal deformation of conductive shaft under different working conditions is analyzed. In order to solve the problems of serious heating and easy ablation of conductive shaft in electrochemical machining of special-shaped deep hole with large aspect ratio, the two schemes of single-sided copper bar and symmetrical copper bar of conductive shaft are studied by ANSYS software. And the speed of spatial planetary movements has no significant effect on the performance of multi-axis EDM. The machining depth and machining efficiency of multi-axis EDM can be increased ulteriorly. Experiment results show that the increase in the amplitude of spatial planetary movements can improve discharge rate and gap status. Machining experiments are carried out to explore the influences of the spatial planetary movement parameters on the machining performance of multi-axis EDM. Then, a multi-axis EDM machine can be controlled to drive a tool electrode to realize the spatial planetary movement. The reliability of the method is confirmed by the simulation. The trajectories of the spatial planetary movements are simulated. Screw theory is used to derive the kinematics of a spatial planetary movement, and the coordinate increments of each axis in an interpolation period can be calculated. This paper proposes a spatial planetary movement method for EDM of inclined holes. Spatial planetary movements of a tool electrode can generate a non-uniform flow field in a discharge gap, promoting the evacuation of debris. However, debris is difficult to be evacuated from a discharge gap, severely affecting the machining efficiency. Multi-axis electrical discharging machining (EDM) is the most commonly used manufacturing method for shrouded blisks. An integrated blisk was finally machined using the proposed method. It was found that the developed electrolyte outlet could be used to enhance the machining stability and the quality of the produced blisk. To determine the optimal parameters of the ECM process, experiments were performed using different electrolytes, outlet shapes, and feed rates. The simulation results showed that the electrolyte outlet mode of the multiple slits was more suitable. The distribution of the groups of holes or slits was optimized. To optimize the flow fields, different shapes of the electrolyte outlet were designed for the tube wall, namely, a continuous outlet in the form of a long and narrow slit and intermittent outlets comprising multiple holes or slits. The method involves the synchronous movement of several designed metal tube electrodes toward the workpiece for the simultaneous electrochemical machining of multiple channels. A highly efficient ECM method for machining the channels of a blisk using multiple tube electrodes is presented. Because a blisk often has several tens to hundreds of blades and only one channel can be machined at a time using current methods, the machining time is long. Electrochemical machining (ECM) is an effective method for machining a blisk.
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