Coupling Model of Electrolytic Proportion and Overcutting Depth in the Construction of Electrolytic Grinding Honeycomb Sealing Faces.

The honeycomb sealing surface serves as the critical sealing structure between the rotor and stator of an engine, and its sealing performance significantly impacts engine efficiency. To address the challenge of effectively controlling the overcutting depth during the electrolytic grinding of honeycomb sealing surfaces, this study quantitatively determined the actual volumetric equivalent electric charge of the honeycomb grid surface based on Faraday's law of electrolysis. Nonlinear fitting was employed to establish the decay characteristics of current density and machining efficiency. Machining experiments were designed with voltage and feed speed set as independent variables, and an empirical model coupling the electrolytic proportion with overcutting depth was fitted on the basis of the obtained experimental results. The new parameters were validated, with the model's predicted values showing an error of approximately 3.5% compared to actual measurements. By selecting the processing parameters using the established empirical prediction model, the overcutting depth of honeycomb seals can be controlled within 0.01 mm while ensuring excellent surface quality, which further meets the high-precision machining requirements for key components such as aviation engine seals.