Electrolytic arc combined machining tool with multi-gear continuously adjustable discharge energy

Abstract

The invention discloses an electrolytic arc combined machining tool with multi-gear continuously adjustable discharge energy. The electrolytic arc combined machining tool comprises a liquid inlet guide sleeve, a spring, a guide rod, an insulation sleeve, a graphite pipe, an electrode handle and an electrode tip. The lower end of the guide rod extends into the graphite pipe, and electrolyte flowing in a gap between the guide rod and the graphite pipe forms an annular resistor. The resistance value of the electrolyte resistor is changed by adjusting the length of the guide rod in the graphite pipe, so that the arc discharge peak current is controlled, and different machining requirements such as high-surface-quality or high-efficiency material removal are met. The electrolyte serves as a current-limiting resistor, multi-gear continuous adjustment of discharge peak current is achieved, an existing electrolyte circulating system is used for heat dissipation, a special cooling device does not need to be additionally arranged, switching of different machining requirements can be rapidly responded, and the equipment cost is effectively reduced while the technology applicability is improved.

Description

Technical Field

[0001] This invention relates to the field of electrolytic arc composite machining technology, and in particular to an electrolytic arc composite machining tool with continuously adjustable discharge energy in multiple levels. Background Technology

[0002] In the field of high-end aerospace equipment manufacturing, the use of difficult-to-machine materials such as titanium alloys, high-temperature alloys, and aluminum-based silicon carbide composites is becoming increasingly widespread. These materials typically possess excellent properties such as high strength, high hardness, and high wear resistance, but they also present challenges when using traditional machining methods, including high cutting forces, rapid tool wear, and low machining efficiency.

[0003] To address these challenges, specialized machining technologies have been widely applied. Among them, arc machining, with its high energy density, can efficiently remove difficult-to-machine materials. However, the intense thermal effects generated during the discharge process can create thermal damage defects such as recast layers and microcracks on the machined surface, severely affecting the surface quality and service performance of the workpiece. In contrast, electrolytic machining removes materials through electrochemical anodic dissolution, characterized by the absence of cutting forces and thermal effects, achieving good surface quality; however, its material removal rate is typically lower.

[0004] To balance processing efficiency and surface quality, electrolytic arc combined machining technology has emerged. This technology aims to combine the high efficiency of arc machining with the superior surface treatment capabilities of electrolytic machining. However, in practice, it has been found that while achieving high-efficiency material removal is relatively easy, obtaining high surface quality presents a significant challenge. The core of this problem lies in the precise control of discharge energy—especially when using DC power. Once an arc is generated, it tends to proliferate and is difficult to disconnect, leading to prolonged high-current discharge, excessive heat output, large-sized electrolytic pits, and deep heat-affected zones. In this case, the depth of thermal damage exceeds the effective finishing capacity of electrolysis, resulting in unsatisfactory workpiece surface quality.

[0005] In existing technologies, a common method to limit the peak discharge current is to connect an external fixed resistor in series in the discharge circuit. This method has significant limitations: the external resistor and its associated switching circuit and heat dissipation device increase the complexity and cost of the system; secondly, due to the limitations of discrete resistor levels, it is difficult to achieve continuous and precise adjustment of the discharge energy, making it unable to flexibly adapt to the full process requirements from roughing to finishing; furthermore, the heat dissipation problem of the external resistor often requires an additional cooling system, further increasing the size and energy consumption of the equipment.

[0006] Therefore, developing a simple, low-cost electrolytic arc composite processing method with continuously adjustable discharge energy has become a key requirement for further development of this technology. This invention presents an innovative solution based on this need. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide an electrolytic arc composite processing tool with continuously adjustable discharge energy in multiple levels, which addresses the shortcomings of existing electrolytic arc composite processing technology, such as complex equipment, discontinuous adjustment, and poor adaptability caused by the use of external fixed resistors.

[0008] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0009] An electrolytic arc composite machining tool with continuously adjustable discharge energy in multiple ranges includes a liquid inlet guide sleeve, a spring, a guide rod, an insulating sleeve, a graphite tube, an electrode handle, and an electrode head.

[0010] The liquid inlet guide sleeve, guide rod, electrode handle, and electrode head are all made of conductive material;

[0011] The liquid inlet guide sleeve includes an outer liquid inlet column, a liquid inlet flange, and an inner liquid inlet column. The outer liquid inlet column and the inner liquid inlet column are both cylindrical, and their diameters are smaller than the diameter of the liquid inlet flange. The outer liquid inlet column, the liquid inlet flange, and the inner liquid inlet column are coaxially and fixedly connected from top to bottom. The liquid inlet guide sleeve has a threaded blind hole at the center of its lower end face, and the liquid inlet guide sleeve has a plurality of through holes for injecting electrolyte evenly distributed around the threaded blind hole on its lower end face.

[0012] The insulating sleeve is a hollow cylinder with openings at both ends, and has an annular protruding shoulder inside.

[0013] The liquid inlet guide sleeve has an inner column that extends into the insulating sleeve from the upper end, with its lower end abutting against the shoulder and its sidewall fitting against the insulating sleeve; the liquid inlet flange of the liquid inlet guide sleeve is coaxially fixed to the upper end of the insulating sleeve.

[0014] The electrode handle comprises an inner electrode column, an electrode flange, and an outer electrode column. The inner and outer electrode columns are both cylindrical, and their diameters are smaller than the diameter of the electrode flange. The inner, outer, and inner electrode columns are coaxially fixed together from top to bottom. The electrode handle has a through hole at the center of its upper end face for electrolyte outflow.

[0015] The liquid inlet column of the electrode handle extends into the insulating sleeve from the lower end of the insulating sleeve, and the side wall fits against the insulating sleeve; the electrode flange of the electrode handle is coaxially fixed to the lower end of the insulating sleeve.

[0016] The graphite tube is tubular and is housed inside an insulating sleeve. One end abuts against the shoulder of the shaft, and the other end abuts against the liquid inlet column of the electrode handle. The sidewall is in contact with the insulating sleeve. The graphite tube is kept insulated from the liquid inlet guide sleeve by the insulating sleeve.

[0017] The upper end of the side wall of the guide rod is provided with an external thread that matches the threaded blind hole of the liquid inlet guide sleeve; the guide rod is set in the insulating sleeve, the upper end is threadedly connected to the threaded blind hole of the liquid inlet guide sleeve, and the lower end extends into the graphite tube, with a gap between the guide rod and the inner wall of the graphite tube. The discharge energy is adjusted by adjusting the length of the guide rod in the graphite tube.

[0018] The spring is installed in the threaded blind hole of the liquid inlet guide sleeve, with one end abutting against the liquid inlet guide sleeve and the other end abutting against the upper end of the guide rod, and is used to provide axial preload for the guide rod to prevent its threaded transmission from loosening;

[0019] The lower ends of the electrode head and the electrode handle are detachably coaxially connected, and the electrode head is provided with a through hole along its axis for the electrolyte to flow out.

[0020] As a further optimization of the electrolytic arc composite processing tool with multi-level continuously adjustable discharge energy of the present invention, the liquid inlet flange of the liquid inlet guide sleeve and the upper end of the insulating sleeve are coaxially fixed together by several bolts, the electrode flange of the electrode handle and the lower end of the insulating sleeve are coaxially fixed together by several bolts, and the electrode head and the lower end of the electrode handle are detachably connected by several bolts.

[0021] As a further optimization of the electrolytic arc composite processing tool with multi-level continuously adjustable discharge energy of the present invention, it also includes an adjustment wrench;

[0022] The lower end of the guide rod has a hexagonal blind hole at its center; the adjusting wrench is used to extend into the graphite tube from the through hole of the electrode head and electrode handle axis and cooperate with the hexagonal blind hole at the lower end of the guide rod to adjust the length of the guide rod inside the graphite tube.

[0023] Compared with the prior art, the present invention, employing the above technical solution, has the following technical effects:

[0024] 1. Achieves flexible and precise control of discharge energy: This invention creatively utilizes the electrolyte flowing inside the tool itself as a current-limiting resistor, and continuously changes its resistance value through a simple mechanical adjustment. This replaces the bulky, discrete external resistor box, allowing operators to quickly and accurately set the optimal discharge energy according to different process requirements such as roughing, semi-finishing, and finishing. This ensures high efficiency while effectively suppressing thermal damage and achieving higher surface quality.

[0025] 2. Simplified system structure and reduced costs: This solution integrates the current-limiting resistor function into the machining tool, eliminating the need for external resistors, switching switches, and dedicated cooling systems. This significantly simplifies the discharge circuit configuration and reduces equipment complexity and manufacturing costs. Simultaneously, the electrolyte circulation system also cools the annular resistor, achieving efficient resource utilization.

[0026] 3. Modular design for easy maintenance: The tool's overall structure adopts a modular component design, allowing each core component, such as the guide rod, graphite tube, and electrode head, to be independently disassembled and replaced. This design greatly simplifies the process of daily maintenance, replacement of worn parts, and troubleshooting, effectively reducing maintenance costs and downtime, and improving the ease of use and lifespan of the equipment. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the exploded structure of the present invention;

[0028] Figure 2 This is a cross-sectional structural diagram of the present invention;

[0029] Figure 3 This is a schematic diagram of the resistance adjustment process in this invention;

[0030] Figures 4(a) and 4(b) are schematic diagrams of the roughing and finishing processes using the tool of the present invention, respectively.

[0031] Figure 5 The diagram shows the simulation results of the internal electric field of this invention.

[0032] In the diagram, 1-liquid inlet guide sleeve, 2-spring, 3-guide rod, 4-insulating sleeve, 5-graphite tube, 6-electrode handle, 7-electrode head. Detailed Implementation

[0033] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings:

[0034] This invention can be implemented in many different forms and should not be considered limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully express the scope of the invention to those skilled in the art. In the drawings, components are enlarged for clarity.

[0035] It should be understood that although the terms first, second, third, etc., may be used herein to describe various elements, components, and / or parts, these elements, components, and / or parts are not limited by these terms. These terms are merely used to distinguish elements, components, and / or parts from one another. Therefore, the first element, component, and / or part discussed below may be a second element, component, or part without departing from the teachings of this invention.

[0036] In the description of this invention, it should be understood that the terms "horizontal," "vertical," "left," "right," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and should not be construed as limiting this invention; the terms "installation," "connection," "fixing," etc., should be interpreted broadly, for example, they can refer to a fixed connection, a detachable connection, or an integral connection, they can refer to a direct connection, an indirect connection through an intermediate medium, or a connection within two components; for those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0037] like Figure 1 and Figure 2 As shown, this invention discloses an electrolytic arc composite machining tool with continuously adjustable discharge energy in multiple ranges. Its features include an inlet guide sleeve, a spring, a guide rod, an insulating sleeve, a graphite tube, an electrode handle, and an electrode head.

[0038] The liquid inlet guide sleeve, guide rod, electrode handle, and electrode head are all made of conductive material;

[0039] The liquid inlet guide sleeve includes an outer liquid inlet column, a liquid inlet flange, and an inner liquid inlet column. The outer liquid inlet column and the inner liquid inlet column are both cylindrical, and their diameters are smaller than the diameter of the liquid inlet flange. The outer liquid inlet column, the liquid inlet flange, and the inner liquid inlet column are coaxially and fixedly connected from top to bottom. The liquid inlet guide sleeve has a threaded blind hole at the center of its lower end face, and the liquid inlet guide sleeve has a plurality of through holes for injecting electrolyte evenly distributed around the threaded blind hole on its lower end face.

[0040] The insulating sleeve is a hollow cylinder with openings at both ends, and has an annular protruding shoulder inside.

[0041] The liquid inlet guide sleeve has an inner column that extends into the insulating sleeve from the upper end, with its lower end abutting against the shoulder and its sidewall fitting against the insulating sleeve; the liquid inlet flange of the liquid inlet guide sleeve is coaxially fixed to the upper end of the insulating sleeve.

[0042] The electrode handle comprises an inner electrode column, an electrode flange, and an outer electrode column. The inner and outer electrode columns are both cylindrical, and their diameters are smaller than the diameter of the electrode flange. The inner, outer, and inner electrode columns are coaxially fixed together from top to bottom. The electrode handle has a through hole at the center of its upper end face for electrolyte outflow.

[0043] The liquid inlet column of the electrode handle extends into the insulating sleeve from the lower end of the insulating sleeve, and the side wall fits against the insulating sleeve; the electrode flange of the electrode handle is coaxially fixed to the lower end of the insulating sleeve.

[0044] The graphite tube is tubular and is housed inside an insulating sleeve. One end abuts against the shoulder of the shaft, and the other end abuts against the liquid inlet column of the electrode handle. The sidewall is in contact with the insulating sleeve. The graphite tube is kept insulated from the liquid inlet guide sleeve by the insulating sleeve.

[0045] The upper end of the side wall of the guide rod is provided with an external thread that matches the threaded blind hole of the liquid inlet guide sleeve; the guide rod is set in the insulating sleeve, the upper end is threadedly connected to the threaded blind hole of the liquid inlet guide sleeve, and the lower end extends into the graphite tube, with a gap between the guide rod and the inner wall of the graphite tube. The discharge energy is adjusted by adjusting the length of the guide rod in the graphite tube.

[0046] The spring is installed in the threaded blind hole of the liquid inlet guide sleeve, with one end abutting against the liquid inlet guide sleeve and the other end abutting against the upper end of the guide rod, and is used to provide axial preload for the guide rod to prevent its threaded transmission from loosening;

[0047] The lower ends of the electrode head and the electrode handle are detachably coaxially connected, and the electrode head is provided with a through hole along its axis for the electrolyte to flow out.

[0048] The upper end of the liquid inlet flange and the insulating sleeve of the liquid inlet guide sleeve are preferably coaxially fixed together by several bolts. The lower end of the electrode flange and the insulating sleeve of the electrode handle are preferably coaxially fixed together by several bolts. The lower end of the electrode head and the electrode handle are preferably detachably connected by several bolts.

[0049] The present invention also includes an adjusting wrench; the lower end of the guide rod is provided with an internal hexagon blind hole; the adjusting wrench is used to extend into the graphite tube from the through hole of the electrode head and electrode handle axis and cooperate with the internal hexagon blind hole at the lower end of the guide rod to adjust the length of the guide rod in the graphite tube.

[0050] When determining the electrolyte, for example, using a 20% sodium chloride aqueous solution with a conductivity of 26.6 S / m at 30℃, the corresponding resistance adjustment scale can be set on the adjusting wrench for easy use.

[0051] An annular gap is formed between the guide rod and the inner wall of the graphite tube. During processing, the electrolyte flows through the annular gap and forms an annular resistor. The resistance value of the annular resistor is controlled by adjusting the depth of the guide rod screwed into the central screw hole.

[0052] Figure 3 This is a schematic diagram illustrating the process of adjusting the resistance value of the built-in electrolyte in this tool using an adjusting wrench, as shown below. Figure 3The adjusting wrench shown is essentially a T-shaped hexagonal wrench, with its hexagonal end engaging with the internal hexagonal blind hole at the bottom of the guide rod. The optical axis of the adjusting wrench is engraved with resistance value markings from 40mΩ to 80mΩ. To increase the resistance, the guide rod is screwed into the center screw hole of the inlet sleeve in the direction it is screwed in. This reduces the length of the guide rod extending into the graphite tube, increasing the resistance of the annular resistor. Conversely, to decrease the resistance, the adjusting wrench is rotated in the opposite direction of screwing in.

[0053] Figures 4(a) and 4(b) illustrate specific implementation methods of using the tool of the present invention in roughing and finishing processes, respectively. After the electrolyte enters the tool cavity through the inlet guide sleeve, it forms an annular resistor in the annular gap between the guide rod and the graphite tube before being sprayed into the machining area. During machining, the inlet guide sleeve is connected to the negative terminal of the power supply, the workpiece is connected to the positive terminal, and the tool rotates in the tool rotation direction and is fed in the feed direction.

[0054] During roughing operations aimed at rapid material removal, the guide rod is unscrewed using the adjusting wrench to reduce the resistance value, thereby generating an arc discharge with a higher peak value and achieving higher discharge energy and material removal rate.

[0055] During finishing operations aimed at achieving high surface quality, the adjusting wrench is screwed into the guide rod to increase the resistance value, thereby generating an arc discharge with a lower peak value, reducing discharge energy, minimizing thermal damage to the workpiece surface, and improving surface quality through the participation of electrolysis.

[0056] Figure 5 The simulation results of the electric field inside the tool are shown. Since the formula for calculating the ring resistance is... In the formula For the electrolyte conductivity, this invention uses a 30%wt NaCl solution at 30℃ with a conductivity of 26.6 S / m; L is the length of the guide rod extending into the graphite tube, D is the inner diameter of the graphite tube (12 mm in this invention), and d is the outer diameter of the guide rod's optical axis (8 mm in this invention). Based on this formula, when the resistance is 40 mΩ, the length of the guide rod extending into the graphite tube is 60.7 mm. To verify the accuracy of this design method, an electric field simulation was performed on the tool's inner cavity with a 60.7 mm extension length. Voltages of 0 V and 5 V were applied to the surface of the inlet conduit and the electrode handle, respectively. The total current obtained was 125.50 A, corresponding to a resistance of 39.84 mΩ. The simulation result showed an error of less than 0.4% compared to the theoretical calculation, proving the effectiveness of this design method.

[0057] This invention creatively utilizes the electrolyte flowing inside the tool itself as a current-limiting resistor, and continuously changes its resistance value through a simple mechanical adjustment method, quickly and accurately setting the optimal discharge energy, flexibly adapting to the needs of the entire process from roughing to finishing; it eliminates the need for external resistors, switching switches, and dedicated cooling systems, significantly simplifying the discharge circuit structure and reducing the complexity and manufacturing cost of the equipment.

[0058] It will be understood by those skilled in the art that, unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It should also be understood that terms such as those defined in general dictionaries should be understood to have the same meaning as in the context of the prior art, and should not be interpreted in an idealized or overly formal sense unless defined as herein.

[0059] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An electrolytic arc hybrid machining tool with multiple stages of continuously adjustable discharge energy, characterized in that, The liquid inlet guide sleeve, spring, guide rod, insulating sleeve, graphite tube, electrode handle and electrode head are made of conductive material. The liquid inlet guide sleeve, guide rod, electrode handle and electrode head are made of conductive material. The liquid inlet guide sleeve comprises a liquid inlet outer column, a liquid inlet flange and a liquid inlet inner column, wherein the liquid inlet outer column and the liquid inlet inner column are both cylindrical, the diameters of the liquid inlet outer column and the liquid inlet inner column are both smaller than the diameter of the liquid inlet flange, and the liquid inlet outer column, the liquid inlet flange and the liquid inlet inner column are coaxially and fixedly connected in sequence from top to bottom; the liquid inlet guide sleeve is provided with a threaded blind hole in the center of its lower end face, and a plurality of through holes for injecting electrolyte are uniformly arranged around the threaded blind hole on the lower end face of the liquid inlet guide sleeve; The insulating sleeve is a hollow cylinder with open ends, and an annular protruding shoulder is arranged in the insulating sleeve. The liquid inlet inner column of the liquid inlet guide sleeve extends into the insulating sleeve from the upper end of the insulating sleeve, the lower end abuts against the shoulder, and the side wall is in close contact with the insulating sleeve; the liquid inlet flange of the liquid inlet guide sleeve is coaxially and fixedly connected with the upper end of the insulating sleeve. The electrode handle comprises an electrode inner column, an electrode flange and an electrode outer column, wherein the electrode inner column and the electrode outer column are both cylindrical, the diameters of the electrode inner column and the electrode outer column are both smaller than the diameter of the electrode flange, and the electrode inner column, the electrode flange and the electrode outer column are coaxially and fixedly connected in sequence from top to bottom; the electrode handle is provided with a through hole for electrolyte outflow in the center of its upper end face; The liquid inlet inner column of the electrode handle extends into the insulating sleeve from the lower end of the insulating sleeve, and the side wall is in close contact with the insulating sleeve; the electrode flange of the electrode handle is coaxially and fixedly connected with the lower end of the insulating sleeve; The graphite tube is tubular and arranged in the insulating sleeve, one end of the graphite tube abuts against the shoulder, the other end abuts against the liquid inlet inner column of the electrode handle, and the side wall is in close contact with the insulating sleeve; the graphite tube is insulated from the liquid inlet guide sleeve by the insulating sleeve; The side wall of the guide rod is provided with an external thread at the upper end, which cooperates with the threaded blind hole of the liquid inlet guide sleeve; the guide rod is arranged in the insulating sleeve, the upper end is threadedly connected with the threaded blind hole of the liquid inlet guide sleeve, and the lower end extends into the graphite tube, leaving a gap between the guide rod and the inner wall of the graphite tube; the length of the guide rod in the graphite tube is adjusted to adjust the discharge energy; The spring is arranged in the threaded blind hole of the liquid inlet guide sleeve, one end of the spring abuts against the liquid inlet guide sleeve, and the other end abuts against the upper end of the guide rod, which provides an axial pre-tightening force for the guide rod to prevent the threaded transmission from loosening; The electrode head is detachably and coaxially connected with the lower end of the electrode handle, and the electrode head is provided with a through hole along its axis for electrolyte outflow.

2. The electric discharge energy multi-step continuously adjustable electro-arc hybrid machining tool according to claim 1, wherein, The liquid inlet flange of the liquid inlet guide sleeve and the upper end of the insulating sleeve are coaxially and fixedly connected by a plurality of bolts, the electrode flange of the electrode handle and the lower end of the insulating sleeve are coaxially and fixedly connected by a plurality of bolts, and the electrode head and the lower end of the electrode handle are detachably connected by a plurality of bolts.

3. The electric discharge energy multi-step continuously adjustable electro-arc hybrid machining tool according to claim 1, wherein, An adjusting wrench is further included. The lower end of the guide rod is provided with an internal hexagonal blind hole; the adjusting wrench is used to extend into the graphite tube from the through hole of the electrode head and electrode handle axis and cooperate with the internal hexagonal blind hole of the lower end of the guide rod to adjust the length of the guide rod in the graphite tube.

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