Electrochemical cutting of mortise-tenon joint structure by rotary tube electrode with helically distributed jet-flow holes

In aero-engines, mortise-tenon joint structures are often used to connect the blades to the turbine disk. The disadvantages associated with conventional manufacturing techniques mean that a low-cost, high-efficiency, and high-quality nickel-based mortise–tenon joint structure is an urgent requirement in the field of aviation engineering. Electrochemical cutting is a potential machining method for manufacturing these parts, as there is no tool degradation in the cutting process and high-quality surfaces can be obtained. To realize the electrochemical cutting of a mortise-tenon joint structure, a method using a tube electrode with helically distributed jet-flow holes on the side-wall is proposed. During feeding, the tube electrode rotates along its central axis. Flow field simulations show that the rotational speed of the tube electrode determines the direct spraying time of the high-speed electrolyte ejected from the jet-flow holes to the machining area, while the electrolyte pressure determines the flow rate of the electrolyte and the velocity of the electrolyte ejected from the jet-flow holes. The machining results using the proposed method are verified experimentally, and the machining parameters are optimized. Finally, mortise and tenon samples are successfully machined using 20 mm thick Inconel 718 alloy with a feeding rate of 5 μm/s.