Arc-mechanical composite cutting processing system and method

Abstract

This invention provides an arc-mechanical composite cutting system and method, including a water tank, a spindle, brushes, a chuck, a chuck, a graphite disc, a worktable, and a controller. A rotary joint is rotatably connected to the spindle, and the spindle is driven to rotate by a motor. The chuck is installed at the bottom end of the spindle, and a transfer tube is installed at the bottom end of the chuck. A rotating cutter composed of a chuck and a graphite disc is installed on the transfer tube. The worktable is located in the space below the rotating cutter, and the workpiece is installed in a water tank on the worktable. The arc cutting process in this invention can efficiently melt and erode materials without significant contact stress. The rotating cutter realizes the arc-mechanical composite cutting process, using the large margin of the arc to remove material while softening part of the base material. Combined with the disc saw to assist cutting, the integrity of the kerf is improved. The processing uses a combination of internal and external flushing fluids. The internal flushing fluid can directly flush the processing area to enhance chip removal and cooling efficiency, reduce the rate of defective discharge, and is highly efficient and practical.

Description

Technical Field

[0001] This invention belongs to the field of cutting and processing technology, specifically relating to an electric arc-mechanical composite cutting and processing system and method. Background Technology

[0002] In the field of aero-engines, high-temperature nickel-based alloys are ideal materials for manufacturing hot-end components due to their superior high-temperature performance and oxidation resistance. Key components, especially blades and bladed disks, are often produced using casting processes to ensure component integrity and material properties. However, casting results in large-volume gating and riser systems, posing significant challenges to subsequent machining. Because of the high hardness and strength of high-temperature nickel-based alloys, traditional abrasive wheel cutting leads to severe tool wear, and the machined workpiece surface often exhibits slag inclusions. These problems significantly increase production costs and reduce machining efficiency.

[0003] Arc machining has garnered widespread attention in the field of special machining due to its high material removal rate. Its energy density is far higher than that of traditional electrical discharge machining (EDM), and it exhibits no significant contact stress, making it particularly suitable for the efficient machining of high-temperature nickel-based alloys. It is considered a potential solution for cutting the gating and riser systems of high-temperature nickel-based alloys. However, the high temperatures and rapid cooling generated during arc machining lead to the formation of more pronounced recast layers, heat-affected layers, and cracks on the workpiece surface, significantly reducing surface quality and potentially negatively impacting the fatigue life of components. Therefore, effectively removing heat-induced surface defects such as recast layers during arc cutting and improving workpiece surface quality has become a pressing technical challenge.

[0004] Based on this, an electric arc-mechanical composite cutting system is proposed. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide an electric arc-mechanical composite cutting system and method to address the shortcomings of the prior art mentioned above.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0007] In a first aspect, an electric arc-mechanical composite cutting system includes a water tank, a spindle, brushes, a chuck, a tray, a graphite disk, a worktable, and a controller.

[0008] The water tank contains working fluid, which is delivered to the tee via pipeline and water pump. The other two passages of the tee are connected to the rotary joint and the adapter, respectively.

[0009] The rotary joint is rotatably connected to the spindle. The spindle is mounted on the insulating slide plate via a first angular contact ball bearing and a second angular contact ball bearing. A motor is also mounted on the insulating slide plate to drive the rotation of the spindle. The chuck is mounted at the bottom of the spindle, and a transfer tube is mounted at the bottom of the chuck. The rotating cutter consisting of a disc and a graphite disc is mounted on the transfer tube.

[0010] The worktable is set in the space below the rotary cutter, and a workpiece is installed in the water tank on the worktable by a clamp. The workpiece is electrically connected to the positive terminal of the DC power supply. A conductive ring is set outside the spindle, and a brush is set on the conductive ring. The brush is electrically connected to the negative terminal of the DC power supply.

[0011] The insulating slide plate and the worktable are respectively signal-connected to the controller, which is signal-connected to the control computer. The control computer schedules the movement of the controller to drive the insulating slide plate and the worktable to complete the cutting operation.

[0012] As a further explanation of the present invention, the disc saw is provided with three saw blades, the graphite disc is provided with three graphite sheets, the three saw blades are fixed at equal intervals in a circular shape on the outside of the groove, the three graphite sheets are fixed at equal intervals in a circular shape on the outside of the boss, the boss is assembled in the groove, and the saw blades and graphite sheets are staggered, and the boss and the groove are fixed to the adapter pipe by screws.

[0013] As a further explanation of the present invention, the boss of the graphite disk is connected to the inner cavity of the adapter tube, and a sealing ring is provided at the connection.

[0014] As a further explanation of the present invention, the graphite disc has three arc-shaped through holes inside the graphite sheet, which connect the inner cavity of the transfer tube to the outside world.

[0015] As a further explanation of the present invention, the saw blade of the circular saw is provided with a cutting edge at the front end, and abrasive grains are provided on both the upper and lower surfaces of the saw blade.

[0016] As a further explanation of the present invention, a first flow meter and a first valve are provided on the connecting pipeline between the water pump and the tee.

[0017] As a further explanation of the present invention, the water tank is also connected to a filter via a pipeline, and the outlet of the filter is connected to the water tank via a pipeline.

[0018] As a further explanation of the present invention, a second flow meter and a second valve are provided on the connecting pipe between the water tank and the filter.

[0019] As a further explanation of the present invention, a main shaft pulley is provided on the main shaft, and a drive pulley is provided on the output shaft of the motor. The drive pulley and the main shaft pulley are connected by a belt ring.

[0020] As a further explanation of the present invention, an oscilloscope is also connected to the positive and negative circuits of the DC power supply for monitoring the processing voltage, and the processing current can be detected synchronously through a current probe.

[0021] Secondly, a processing method for an electric arc-mechanical composite cutting system includes the following steps:

[0022] The workpiece is mounted in the water tank on the worktable by a fixture. The computer scheduling controller drives the insulated slide plate and the worktable to move, so that the rotary tool rotates and moves closer to the workpiece.

[0023] When the graphite disk rotates and faces the workpiece, it generates an electric arc plasma under the action of DC power supply. The high temperature generated can quickly melt the workpiece and initially form a kerf.

[0024] During the movement, the partially molten material re-adheres to the workpiece surface to form a recast layer. As the rotating cutter continues to rotate and feed, the saw blade of the circular saw begins to contact the workpiece. The saw blade tip cuts and removes the initially formed softened recast layer and part of the preheated base material.

[0025] During the rotation of the rotary cutter, the disc saw and graphite disc rotate, forming a recast layer at the front end of the workpiece kerf. Due to the larger cross-sectional area of ​​the graphite disc, a recast layer is also generated on the upper and lower surfaces of the workpiece kerf. The disc saw blade is equipped with a cutting edge at the front end, and abrasive grains are provided on both the upper and lower surfaces of the saw blade. When the disc saw blade enters the kerf, it simultaneously grinds the upper and lower surfaces of the kerf, while continuously grinding the material surface of the workpiece.

[0026] During the cutting process, the arc-shaped through hole can connect the inner cavity of the transfer tube with the outside. When the internal flushing fluid flows into the inner hole of the transfer tube, it can flow into the kerf along the arc-shaped through hole of the graphite sheet. When the graphite disk rotates to face the kerf, the inner hole of its graphite sheet faces the front end of the processing area, cooling the processing surface and flushing away the electro-erosion particles. The external flushing fluid is arranged at the horizontal plane of the kerf and enters the processing gap by using the centrifugal force of the rotating tool. Together with the internal flushing fluid, it flushes the electro-erosion particles out of the processing area more quickly, improving processing stability and completing the cutting operation.

[0027] Compared with the prior art, the present invention has the following advantages:

[0028] The arc cutting process in this invention can efficiently melt and erode materials without significant contact stress. A combined arc-mechanical cutting process is achieved through a rotating cutter, utilizing the large margin of the arc to remove material while softening part of the base material. Combined with a disc saw for assisted cutting, the integrity of the kerf is improved. The abrasive particles on the upper and lower surfaces of the disc saw can easily remove thermally induced surface defects such as recast layers when they are initially formed, reducing grinding force and improving the surface quality of castings and recycled cutting materials. Processing is achieved using a combination of internal and external flushing fluids. The internal flushing fluid directly washes the processing area, enhancing chip removal and cooling efficiency and reducing the rate of defective discharges. The external flushing fluid, combined with the electrode rotation, can also enter the processing area to assist in chip removal and cooling, making the processing process more stable and reliable. This allows the process to adapt to complex working conditions with deep and narrow kerfs, making it highly efficient and practical. Attached Figure Description

[0029] Figure 1 This is an overall schematic diagram of the invention;

[0030] Figure 2 This is an exploded view of the rotating cutting tool structure of the present invention;

[0031] Figure 3 This is a perspective view of the graphite disk structure of the present invention;

[0032] Figure 4 This is a top view of the rotary tool machining process of the present invention;

[0033] Figure 5 This is a side view of the rotary tool machining process of the present invention;

[0034] Figure 6 This is a schematic diagram of the working process of the rotating cutter and the external flushing fluid of the present invention.

[0035] Explanation of reference numerals in the attached figures:

[0036] 1-Water tank; 2-Working fluid; 3-Water pump; 4-First flow meter; 5-First valve; 6-T-way; 7-Rotary joint; 8-Spindle; 9-Conductive ring; 10-Brush; 11-First angular contact ball bearing; 12-Pulley; 13-Belt; 14-Pulley; 15-Motor; 16-Second angular contact ball bearing; 17-Chuck; 18-Adapter; 19-External flushing fluid; 20-Adapter pipe; 21-Circular saw; 22-Graphite disc; 23-Insulating slide plate; 24-Clamp; 25-Workpiece; 26-Water tank; 27-Workbench; 28-Oscilloscope; 29-DC power supply; 30-Second flow meter; 31-Second valve; 32-Filter; 33-Control computer; 34-Controller; 35-Sealing ring; 36-Screw; 37-Plasma; 38-Recasting layer; 39-Electro-erosion particles. Detailed Implementation

[0037] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0038] like Figure 1-6 As shown, the present invention provides a technical solution: an electric arc-mechanical composite cutting processing system, including a water tank 1, a spindle 8, an electric brush 10, a chuck 17, a collet 21, a graphite disk 22, a worktable 27 and a controller 34;

[0039] The water tank 1 contains working fluid 2, which is delivered to the tee 6 via a pipeline and a water pump 3. A first flow meter 4 and a first valve 5 are installed on the connecting pipeline between the water pump 3 and the tee 6 to control the flow rate of the working fluid 2.

[0040] The other two passages of the three-way connector 6 are connected to the rotary joint 7 and the adapter 18 respectively. A portion of the working fluid 2 flows into the machine tool's internal flow channel through the rotary joint 7 and passes through the inner hole of the spindle 8 to form an internal flushing fluid. Another portion of the working fluid 2 flows into the adapter 18 and forms an external flushing fluid 19.

[0041] The rotary joint 7 is rotatably connected to the main shaft 8. The main shaft 8 is mounted on the insulating slide plate 24 via a first angular contact ball bearing 11 and a second angular contact ball bearing 16. A motor 15 is also mounted on the insulating slide plate 24, which drives the rotation of the main shaft 8. A main shaft pulley 12 is provided on the main shaft 8, and a drive pulley 14 is provided on the output shaft of the motor 15. The drive pulley 14 and the main shaft pulley 12 are drivenly connected by a belt ring 13.

[0042] The chuck 17 is installed at the bottom end of the spindle 8, and a transfer tube 20 is installed at the bottom end of the chuck 17. The rotating tool composed of the coil 21 and the graphite disk 22 is installed on the transfer tube 20.

[0043] The circular saw 21 is provided with three saw blades, and the graphite disc 22 is provided with three graphite sheets. The three saw blades are fixed in a circumferential shape at equal intervals on the outside of the groove, and the three graphite sheets are fixed in a circumferential shape at equal intervals on the outside of the boss. The boss is assembled in the groove, and the saw blades and graphite sheets are staggered. The boss and the groove are fixed to the adapter pipe 20 by screws 36.

[0044] The workbench 27 is located in the space below the rotating cutter, and the workpiece 25 is installed in the water tank 26 on the workbench 27 by means of a clamp 24. The water tank 26 is also connected to a filter 32 through a pipeline. The outlet of the filter 32 is connected to the water tank 1 through a pipeline. A second flow meter 30 and a second valve 31 are provided on the connecting pipeline between the water tank 26 and the filter 32.

[0045] The workpiece 25 is electrically connected to the positive terminal of the DC power supply 29. A conductive ring 9 is provided outside the spindle 8. A brush 10 is provided on the conductive ring 9. The brush 10 is electrically connected to the negative terminal of the DC power supply 29.

[0046] The insulating slide plate 24 and the worktable 27 are respectively signal-connected to the controller 34, and the controller 34 is signal-connected to the control computer 33. The cutting operation can be completed by the control computer 33 scheduling the controller 34 to drive the movement of the insulating slide plate 23 and the worktable 27.

[0047] An oscilloscope 28 is also connected to the positive and negative circuits of the DC power supply 29 to monitor the processing voltage, and the processing current can be detected synchronously through a current probe.

[0048] The processing method of the above-mentioned arc-mechanical composite cutting system includes the following steps:

[0049] During use, the control computer 33 schedules the controller 34 to drive the movement of the insulating slide plate 23 and the worktable 27, causing the rotating cutter to rotate and move closer to the workpiece 25. When the graphite disk 22 rotates and faces the workpiece 25, an electric arc plasma 37 is generated under the action of the DC power supply 29. The generated high temperature can quickly melt the workpiece 25 and initially form a kerf. Due to the large volume of the molten material and the small gap, some of the molten material re-adheres to the surface of the workpiece 25 during the movement to form a recast layer 38. As the cutter continues to rotate and feed, the saw blade of the circular saw 21 begins to contact the workpiece 25. The saw blade cutting edge removes the initially formed softened recast layer and part of the preheated base material, thereby improving the surface integrity of the kerf. Although there is also a discharge gap between the circular saw 21 and the workpiece 25, the contact area between the cutting edge and the workpiece 25 is very small, and the probability of discharge is very low and can be ignored.

[0050] During the rotation of the rotary cutter, the disc saw 21 and the graphite disc 22 rotate, forming a recast layer 38 at the front end of the kerf on the workpiece 25. Since the graphite disc 22 has a higher cross-sectional area, a recast layer 38 is also generated on the upper and lower surfaces of the kerf on the workpiece 25. The saw blade of the disc saw 21 is equipped with a cutting edge at the front end, and abrasive grains are provided on both the upper and lower surfaces of the saw blade for grinding during the cutting process. When the saw blade of the disc saw 21 enters the kerf, the upper and lower surfaces of the kerf are ground simultaneously. Since the recast layer 38 is initially formed and the material is preheated and softened, there is no significant grinding force. The disc saw 21 not only removes the recast layer 38, but also continuously grinds the surface of the workpiece 25 material, thereby improving the processing quality of the casting surface and the surface of the recycled material.

[0051] Because the kerf is narrow and deep during the cutting process, it is difficult to discharge the processed product in time by relying solely on the external flushing fluid 19, which may lead to short circuits and increased blade wear, while reducing processing efficiency and surface quality. The boss of the graphite disk 22 is connected to the inner cavity of the adapter tube 20, and a sealing ring 35 is provided at the connection point to perform sealing operations. The graphite sheet of the graphite disk 22 is provided with three arc-shaped through holes, which complete the connection between the inner cavity of the adapter tube 20 and the outside. When the internal flushing fluid flows into the inner hole of the adapter tube 20, it can flow into the kerf through the arc-shaped through holes of the graphite sheet.

[0052] When the graphite disk 22 rotates to face the kerf, the inner hole of its graphite sheet faces the front end of the processing area, cooling the processing surface and flushing the electro-erosion particles 39. The external flushing fluid 19 is arranged at the horizontal plane of the kerf, and uses the centrifugal force of the rotating tool to enter the narrow processing gap. Together with the internal flushing fluid, it flushes the electro-erosion particles 39 out of the processing area more quickly, improving processing stability.

[0053] In addition, after the graphite disc 22 rotates out the kerf, it can continue to act on the processing area to assist in chip removal and cool the front cutting edge of the disc saw 21.

[0054] The arc cutting process in this embodiment can efficiently melt and erode materials without significant contact stress. A combined arc-mechanical cutting process is achieved through a rotating cutter, utilizing the large margin of the arc to remove material while softening part of the base material. Combined with the auxiliary cutting of the disc saw 21, the integrity of the kerf is improved. The abrasive particles on the upper and lower surfaces of the disc saw 21 can easily remove thermally induced surface defects such as the recast layer when they initially form, reducing grinding force and improving the surface quality of castings and recycled cutting materials. Processing is performed using a combination of internal and external flushing fluids. The internal flushing fluid directly washes the processing area, enhancing chip removal and cooling efficiency and reducing the rate of defective discharges. The external flushing fluid, combined with the electrode rotation, can also enter the processing area to assist in chip removal and cooling, making the processing process more stable and reliable. This process can adapt to complex working conditions with deep and narrow kerfs, making it highly efficient and practical.

[0055] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0056] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An electric arc-mechanical composite cutting system, characterized in that: Includes a water tank (1), a spindle (8), a brush (10), a chuck (17), a circular saw (21), a graphite disc (22), a worktable (27), and a controller (34); The water tank (1) contains working fluid (2), and the working fluid (2) in the water tank (1) is sent to the tee (6) through the pipeline and the water pump (3). The other two passages of the tee (6) are connected to the rotary joint (7) and the adapter (18) respectively. The rotary joint (7) is rotatably connected to the main shaft (8). The main shaft (8) is mounted on the insulating slide plate (23) via the first angular contact ball bearing (11) and the second angular contact ball bearing (16). The insulating slide plate (23) is also equipped with a motor (15), which drives the rotation of the main shaft (8). The chuck (17) is mounted on the bottom end of the main shaft (8). The bottom end of the chuck (17) is equipped with a transfer tube (20). The rotating cutter consisting of the disc saw (21) and the graphite disc (22) is mounted on the transfer tube (20). The circular saw (21) is provided with three saw blades, and the graphite disc (22) is provided with three graphite sheets. The three saw blades are fixed in a circumferential shape at equal intervals on the outside of the groove, and the three graphite sheets are fixed in a circumferential shape at equal intervals on the outside of the boss. The boss is assembled in the groove, and the saw blades and graphite sheets are staggered. The boss and the groove are fixed to the adapter pipe (20) by screws (36). The boss of the graphite disc (22) is connected to the inner cavity of the adapter pipe (20), and a sealing ring (35) is provided at the connection. The graphite sheets of the graphite disc (22) are provided with three arc-shaped through holes, and the inner cavity of the adapter pipe (20) is connected to the outside through the arc-shaped through holes. The saw blade of the circular saw (21) is provided with a cutting edge at the front end, and abrasive grains are provided on the upper and lower surfaces of the saw blade. The worktable (27) is located in the space below the rotary cutter, and a workpiece (25) is installed in the water tank (26) on the worktable (27) by a clamp (24). The workpiece (25) is electrically connected to the positive terminal of the DC power supply (29). A conductive ring (9) is provided outside the spindle (8), and a brush (10) is provided on the conductive ring (9). The brush (10) is electrically connected to the negative terminal of the DC power supply (29). The insulating slide plate (23) and the worktable (27) are respectively connected to the controller (34). The controller (34) is connected to the control computer (33). The control computer (33) schedules the controller (34) to drive the movement of the insulating slide plate (23) and the worktable (27) to complete the cutting operation.

2. The arc-mechanical composite cutting system according to claim 1, characterized in that, A first flow meter (4) and a first valve (5) are installed on the connecting pipeline between the water pump (3) and the tee (6).

3. The arc-mechanical composite cutting system according to claim 1, characterized in that, The water tank (26) is also connected to a filter (32) through a pipeline. The outlet of the filter (32) is connected to the water tank (1) through a pipeline. A second flow meter (30) and a second valve (31) are installed on the connecting pipeline between the water tank (26) and the filter (32).

4. The arc-mechanical composite cutting system according to claim 1, characterized in that, The main shaft (8) is provided with a main shaft pulley (12), and the output shaft of the motor (15) is provided with a drive pulley (14). The drive pulley (14) and the main shaft pulley (12) are connected by a belt ring (13).

5. The arc-mechanical composite cutting system according to claim 1, characterized in that, An oscilloscope (28) is also connected to the positive and negative circuits of the DC power supply (29) to monitor the processing voltage, and the processing current can be detected synchronously through the current probe.

6. A processing method for an arc-mechanical composite cutting system according to any one of claims 1-5, characterized in that, Includes the following steps: The workpiece (25) is installed in the water tank (26) on the worktable (27) by the fixture (24). The control computer (33) schedules the controller (34) to drive the insulated slide plate (23) and the worktable (27) to move, so that the rotary tool rotates and moves closer to the workpiece (25). When the graphite disk (22) rotates to face the workpiece (25), an electric arc plasma (37) is generated under the action of the DC power supply (29). The high temperature generated can quickly melt the workpiece (25) and initially form a kerf. During the movement, the partially molten material re-adheres to the surface of the workpiece (25) to form a recast layer (38). As the rotating cutter continues to rotate and feed, the saw blade of the disc saw (21) begins to contact the workpiece (25). The softened recast layer and part of the preheated matrix material are removed by cutting at the cutting edge of the saw blade. During the rotation of the rotary cutter, the disc saw (21) and the graphite disc (22) are rotated, forming a recast layer (38) at the front end of the kerf of the workpiece (25). Since the cross-sectional area of ​​the graphite disc (25) is larger, a recast layer (38) will also be generated on the upper and lower surfaces of the kerf of the workpiece (25). The saw blade of the disc saw (21) is provided with a cutting edge at the front end. Abrasive grains are provided on the upper and lower surfaces of the saw blade. When the saw blade of the disc saw (21) enters the kerf, the upper and lower surfaces of the kerf are ground simultaneously, and the material surface of the workpiece (25) is continuously ground at the same time. During the cutting process, the arc-shaped through hole can connect the inner cavity of the adapter pipe (20) with the outside. When the inner flushing fluid flows into the inner hole of the adapter pipe (20), the inner flushing fluid can flow into the kerf along the arc-shaped through hole of the graphite sheet. When the graphite disk (22) rotates to face the kerf, the inner hole of its graphite sheet faces the front end of the processing area, cooling the processing surface and flushing the electro-erosion particles (39). The outer flushing fluid (19) is arranged at the horizontal plane of the kerf and enters the processing gap by using the centrifugal force of the rotating tool. Together with the inner flushing fluid, it flushes the electro-erosion particles (39) out of the processing area more quickly, improves the processing stability, and completes the cutting operation.

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