Patent ID: 8262897

Claim:
A method for producing aerodynamic structures in manufacturing of integrally-bladed gas turbine rotors, aerodynamic structures of the integrally-bladed gas turbine rotor being able to be produced to final contour precision on a rotor-disk workpiece blank by electrochemically machining in an electrochemical sinking process, through a precise electro chemical machining (PECM) process, comprising the following steps: preparing a rotor-disk workpiece blank made of a material, the material being not readily machine-cut; removing from the rotor-disk workpiece blank the material between intended blades to a selected machining over-allowance; providing at least one tool electrode for finish-machining at least one aerodynamic structure of an integrally bladed gas turbine rotor from the rotor-disk workpiece blank, a contour of the tool electrode being adapted to a contour of the aerodynamic structure to be produced using the tool electrode in such a way that, during the electrochemical sinking process, a gap of similar size is maintained between the rotor-disk workpiece blank and the tool electrode; electrochemically machining the aerodynamic structure from the rotor-disk workpiece blank in the electrochemical sinking process by placing the rotor-disk workpiece blank and the tool electrode in an electrolyte and by applying a voltage or a current, the applied current or the applied voltage being time pulsed; and forced rinsing of the gap filled with electrolyte between the rotor-disk workpiece blank and the tool electrode in response to a pulsating motion of the tool electrode.