nozzle

Abstract

A nozzle for an electrochemical machining apparatus is provided, the nozzle defining a body having releasably attachable first and second body portions which, when attached to one another, define an electrolyte cavity therebetween, the body including an inlet port upstream of the cavity and an outlet port for, in use, discharging a jet of electrolyte toward a surface of a workpiece, the body defining a flow path from the inlet port through the cavity to the outlet port.

Description

Technical Field

[0002]

[0001] The present disclosure relates to a nozzle for an electrochemical machining apparatus and an electrochemical machining apparatus.

Background Art

[0002] Electrochemical machining is a well-known process for selectively machining the surface of a workpiece. By this machining method, as long as the surface material is conductive, the surface can be machined by an electrochemical reaction. The roughening enabled by electrochemical machining improves the adhesiveness for mounting components and / or applying coatings to the surface. Surface machining can also be used to modify the optical and / or frictional properties of the surface, reveal the grain boundaries of the surface microstructure, or polish the surface to produce a homogeneous surface finish.

[0003] Electrochemical jet machining is a form of electrochemical machining that involves discharging a stream or jet of electrolyte from a nozzle towards a surface while applying a voltage between components of an electrochemical machining apparatus, such as between the nozzle and the workpiece surface. The electrolytic current between the anode surface and the cathode nozzle is supplied by the electrolyte jet discharged from the nozzle. The design of the nozzle results in both the flow characteristics of the electrolyte jet and the current density distribution across the jet. The manufacture of well-known nozzles that produce the desired flow characteristics and current density distribution can be difficult due to the complex nature of nozzle design.

[0004] The present disclosure aims to overcome or at least mitigate one or more problems associated with the prior art.

Summary of the Invention

[0005] A first aspect of this teaching provides a nozzle for an electrochemical processing apparatus. The nozzle defines a body comprising an internal cavity for receiving an electrolyte therein, an inlet port located upstream of the cavity and flowing with it for discharging the electrolyte into the cavity, and an outlet port for discharging a jet of electrolyte toward the surface of a workpiece when in use, wherein the outlet port is located downstream of the cavity and flowing with it so as to define a flow path from the inlet port through the cavity to the outlet port, and the body comprises first and second body parts that are removably mountable, wherein when the first and second body parts are mounted together they form a cavity between them.

[0006] The nozzle body is constructed from two removably attachable parts, which simplifies the manufacturing of the nozzle. This configuration allows the internal nozzle structure to be precisely machined to provide the required flow characteristics of the electrolyte jet.

[0007] The first and second main bodies may be configured and positioned to form a seal between them that encloses a cavity when the first and second main bodies are attached to each other.

[0008] Adding a seal around the cavity helps reduce leakage, which ensures that all of the electrolyte is directed towards the outlet port.

[0009] This seal configuration automatically forms a seal between the first and second main body parts when they are attached to each other.

[0010] The first and second main body portions may include first and second seal-forming portions.

[0011] The first and second seal-forming portions may include a convex portion in the first or second main body portion and a corresponding recess in the other of the first or second main body portion.

[0012] A sealant may be applied to the recessed areas.

[0013] The applied sealant can only partially fill the recess.

[0014] The sealant may consist of a polyurethane sealant or a silicone sealant.

[0015] Providing the first and second seal-forming portions in the form of recesses and corresponding protrusions provides alignment characteristics and facilitates the assembly of the first and second main body portions.

[0016] The first and second main body portions may be configured and arranged to form a labyrinth seal between them.

[0017] Because the outflow of electrolytes is restricted by the meandering outlet path through which the electrolytes must pass, the combination of sealing elements (i.e., protrusions and recesses) forms a strong seal within the body.

[0018] The first and second main bodies can define the first and second opposing cavity walls.

[0019] The first and second opposing cavity walls may be tapered in the direction toward the exit port.

[0020] Advantageously, this configuration helps direct the electrolyte flow towards the outlet port to provide more laminar flow.

[0021] The first and second cavity walls may be tapered to a minimum separation distance away from the outlet port. The first and second cavity walls may be tapered to a minimum separation distance so as to define a throat portion at a position away from the outlet port.

[0022] Reducing the distance between opposing walls of the cavity helps increase the velocity of the electrolyte flowing toward the exit port.

[0023] The first and second opposing cavity walls may expand along a predetermined direction between the throat portion and the outlet port such that the separation distance between the first opposing cavity wall and the second opposing cavity wall increases.

[0024] This downstream expansion end has been found to have a stabilizing effect on the flow of the electrolyte.

[0025] Furthermore, having a minimum separation distance between the opposing walls of the cavity spaced apart from the outlet port helps prevent the electrolyte from blocking the outlet port due to the surface tension of the electrolyte.

[0026] Each of the first and second opposing cavity walls may include side wall portions that define cavity side walls when the first and second body portions are attached to each other.

[0027] The cavity side walls may be tapered in a direction toward the outlet port.

[0028] The cavity side walls may be tapered from a maximum separation distance proximate to the inlet port.

[0029] The cavity side walls may be tapered to a minimum separation distance proximate to the outlet port.

[0030] The outlet region of the cavity side walls proximate to the outlet port may curve inwardly.

[0031] The outlet region having an inwardly curved side wall may be directly upstream of the outlet port, for example, directly above.

[0032] This increases the resistance to the electrolyte jet stream at the lateral edge portion of the outlet port. This also helps equalize the machining effect across the width of the electrolyte jet, otherwise the machining rate would be high in these side regions.

[0033] The body may have an end face that, when in use, is intended to substantially enclose the outlet port and be positioned opposite the surface of the workpiece. This end face may define a substantially planar region surrounding the outlet port.

[0034] The substantially planar area may be intended to face the surface of the workpiece during use.

[0035] The surface area is designed to provide a specific area that optimizes the interaction of potentials observed on the surface, in this case, to provide a uniform application of machining operations across the width of the surface.

[0036] The body may have end faces intended to substantially enclose the outlet port and be positioned facing the surface of the workpiece during use. The end faces may be substantially non-planar.

[0037] The end face may have a lateral region that is at least partially curved or tapered toward the inner region of the end face.

[0038] This helps to equalize the machining effect across the nozzle width, without which the machining rate would be higher at the jet edges due to flow effects and charge concentration. This deformation helps to counteract the effect of substantially increased resistance at the outer edges of the jet stream, which reduces mechanical efficiency, thereby equalizing the effect across the entire width of the jet.

[0039] The inner region may be curved such that its end face defines a continuous curved surface.

[0040] The inner region may be substantially planar.

[0041] The inner region may be curved or inclined such that it forms a concave region on the end face.

[0042] The end face of the nozzle may be triangular, trapezoidal, semicircular, hexagonal, oval, or elliptical in side view or cross-section.

[0043] The end face of the nozzle may have an uneven surface.

[0044] The main unit may have an outlet spout surrounding the outlet port.

[0045] The external region of the body adjacent to the outlet spout, for example, the area above the outlet spout, may be tapered or chamfered.

[0046] The first and second main body portions may have first and second outer surfaces.

[0047] The first and second outer surfaces may define tapered or chamfered areas intended to be positioned at the top, or directly above, the outlet port, i.e., the outlet spout, during use.

[0048] This bottom chamfered region deflects the incoming liquid away from the electrolyte jet. Therefore, this chamfered region is designed to minimize splashing from the jet fluid, which would otherwise result in a secondary processing effect caused by the fluid reflecting off the workpiece surface and then back onto the surface from the nozzle.

[0049] The nozzle may have a mounting configuration that allows the first and second main body portions to be releasably attached.

[0050] The mounting configuration may include at least one hole in each of the first and second main body sections for receiving fasteners that pass through it.

[0051] The mounting configuration can form a mounting configuration for attaching the nozzle to an electrochemical processing apparatus.

[0052] The exit port may be defined by the distance between the first body and the second body.

[0053] The exit port may be located on the surface of the main body that is intended to be at the bottom during use.

[0054] The main body may be formed from a conductive material.

[0055] The main body may be made of metal or a metal alloy, such as steel.

[0056] The outlet port may have a width ranging from 1 mm to 25 mm. The outlet port may have a width ranging from 5 mm to 20 mm. The width may be approximately 10 mm.

[0057] The outlet port may have a depth in the range of 0.01 mm to 1 mm. The outlet port may have a depth in the range of 0.05 mm to 0.5 mm. The depth may be approximately 0.2 mm.

[0058] The exit port may be approximately rectangular.

[0059] A second aspect of this instruction provides an electrochemical processing apparatus for processing the surface of a workpiece. The electrochemical processing apparatus comprises an electrolyte source and a nozzle according to the first aspect, configured and positioned to receive an electrolyte from the electrolyte source through an inlet port and to discharge an electrolyte jet from an outlet port toward the surface of the workpiece when in use.

[0060] The electrochemical processing apparatus may be configured to apply a charge to the nozzle and to the surface of the workpiece such that, during use, the nozzle and the surface define the first and second electrodes of the electrolytic cell.

[0061] The nozzle can be positioned so as to be spaced away from the surface of the workpiece during use.

[0062] An electrochemical processing apparatus may include contact electrodes configured and positioned to contact the surface of a workpiece and conduct an electric current therein during use.

[0063] The electrochemical processing apparatus may be equipped with a second nozzle according to the first embodiment.

[0064] The electrochemical processing apparatus may be equipped with a second electrolyte source.

[0065] Each of the two nozzles can be configured to dispense a different electrolyte. [Brief explanation of the drawing]

[0066] [Figure 1] Figure 1 is a schematic diagram of an electrochemical processing apparatus according to an embodiment. [Figure 2] Figure 2 shows the processing unit of the electrochemical processing apparatus shown in Figure 1, and the processing unit is operated by a robotic arm. [Figure 3] Figure 3 is an isometric view of the nozzle of the electrochemical processing apparatus shown in Figure 1. [Figure 4] Figure 4 is an isometric view of a section of the nozzle shown in Figure 3. [Figure 5] Figure 5 is a side view of the nozzle shown in Figure 3. [Figure 6] Figure 6 is a cross-sectional side view of the nozzle shown in Figure 3. [Figure 7A] Figure 7A is a front view of the first main body of the nozzle shown in Figure 3. [Figure 7B] Figure 7B is a front view of the second main body of the nozzle shown in Figure 3. [Figure 8] Figure 8 is a front view of the nozzle body shown in Figure 3. [Figure 9A] Figure 9A is a front view of the first main body of the nozzle according to the embodiment. [Figure 9B] Figure 9B is a front view of the first main body of the nozzle according to the embodiment. [Figure 9C] Figure 9C is a front view of the first main body of the nozzle according to the embodiment. [Modes for carrying out the invention]

[0067] Here, an embodiment will be described with reference to the attached drawings.

[0068] First, referring to Figure 1, an electrochemical processing apparatus is illustrated and is denoted as 10 in its entirety. The electrochemical processing apparatus 10 includes a base unit 12 and a processing unit 14. It can be seen that the processing unit 14 is intended to be handheld and may be operated by a robotic arm or remotely driven to traverse a surface.

[0069] The base unit 12 and the processing unit 14 are connected via a supply pipe 16, through which the base unit 12 can supply power and electrolytes to the processing unit 14. By connecting the processing unit 14 to the base unit 12 via the flexible supply pipe 16, the processing unit 14 becomes movable independently of the base unit 12. In other words, the processing unit 14 is provided as a portable unit. This configuration allows the device 10 to be moved and make contact with the surface 18 of a workpiece, that is, it can be used on-site as part of a movable device or as part of a fixed-position processing system.

[0070] In an alternative configuration, the processing unit 14 may be substantially fixed in place. In this configuration, the electrochemical processing apparatus 10 may not include a separate base unit 12 and processing unit 14, but may be provided as a standalone unit fixed in place, with the workpiece positioned below the processing unit for processing.

[0071] The electrochemical processing apparatus 10 includes a nozzle 22. The nozzle 22 may be located within the processing unit 14. In the configuration described, the nozzle 22 is located within the housing 20 of the processing unit 14. The nozzle 22 is configured to discharge an electrolyte jet 24 toward the surface 18 of the workpiece.

[0072] The housing 20, when positioned relative to the workpiece surface 18, is configured to define an enclosed working space. It should be noted that the nozzles 22 may be removably mounted inside the housing 20, allowing different nozzles to be used for different machining operations. In some alternative configurations, the housing 20 may not be provided.

[0073] The electrochemical processing apparatus 10 includes an electrolyte source 26 for supplying an electrolyte to a nozzle 22. In the configuration described, the electrolyte source is an electrolyte reservoir 26. The electrolyte reservoir (electrolyte source) 26 may be located within the base unit 12. The nozzle 22 is configured and positioned to receive the electrolyte from the electrolyte source 26 through an inlet and discharge an electrolyte jet 24 from an outlet toward the surface of the workpiece when in use.

[0074] The electrolyte may be an aqueous electrolyte. The electrolyte may be provided as an aqueous solution containing one or more water-salt solutions, such as sodium nitrate, sodium chloride, or sodium iodide. It should be seen that any suitable electrolyte, such as substantially anhydrous ionic solvents, may be used.

[0075] The electrochemical processing apparatus 10 is configured to apply electric charge to the nozzle 22 and the surface 18. In this way, the nozzle 22 and the surface 18 form the first and second electrodes of the electrolytic cell.

[0076] The nozzle 22 may be conductive. In other words, the nozzle 22 may be formed from a conductive material. The nozzle 22 may be formed from a metal or metal alloy, for example, steel. In an alternative configuration, the electrochemical processing apparatus 10 may include an additional electrode separate from the nozzle 22, and the electrochemical processing apparatus 10 may be configured to apply a charge to the additional electrode and surface 18. In this alternative configuration, the nozzle 22 may be formed from any suitable material.

[0077] The electrochemical processing apparatus 10 includes a contact electrode 28 configured and positioned to contact at least a portion of the surface 18 during use. This contact electrode 28 allows the electrochemical processing apparatus 10 to apply an electric charge to the surface 18. In this way, the surface 18 and the nozzle 22 can form an electrolytic cell that enables electrochemical processing.

[0078] The nozzle 22 is positioned in the electrochemical processing apparatus 10 (for example, within the housing 20) so as to be spaced away from the surface 18 when in use. The distance between the electrode 22 and the workpiece surface 18 (i.e., the inter-electrode gap) affects the processing of the surface 18. The nozzle 22 is movable relative to the surface 18 so as to move on the surface 18 and / or adjust the distance between the nozzle 22 and the surface 18.

[0079] To enable the application of electric charge to the nozzle 22 and surface 18 (i.e., via the contact electrode 28), the electrochemical processing apparatus 10 includes a power supply 30. It should be noted that to power the electrochemical processing apparatus 10, the power supply 30 may include one or more batteries or may be connectable to an external power source.

[0080] Material removal and deposition are achieved by supplying an electrolyte through the nozzle 22 and spraying it toward the surface 18. A potential is applied between the nozzle 22 and the surface 18, resulting in anode dissolution of the surface 18 or deposition on the surface 18. In the first operating mode, a negative charge is applied to the nozzle 22 and a positive charge is applied to the surface 18. In this first operating mode, the apparatus 10 scrapes the surface 18 to change its topography. In the second operating mode, a positive charge is applied to the nozzle 22 and a negative charge is applied to the surface 18. In this second operating mode, a material (e.g., silica particles or additive coatings that enable surface functionalization) can be deposited on the surface 18, thereby changing its surface topography.

[0081] Although not shown, in an alternative configuration, the electrochemical processing apparatus 10 may include a second nozzle 22 for discharging the electrolyte jet 24 onto the workpiece surface 18. This allows for a greater degree of control over surface topography formation and optimization cycle time by utilizing a dual electrolyte jet. In this configuration, both the first and second nozzles 22 may be configured to discharge the same electrolyte. Alternatively, the electrochemical processing apparatus 10 may include a second electrolyte source, and the two nozzles 22 may be configured to discharge different electrolytes.

[0082] Referring to Figure 2, the processing unit 14 is movable relative to the base unit (not shown) and is operated by a robotic arm 15. The processing unit 14 is connected to the base unit via a supply pipe 16. It can be seen that the robotic arm 15 may be provided as part of an automated production line.

[0083] The machining unit 14 in Figure 2 is configured to be movable onto the workpiece surface 18 by the robot arm 15 without requiring the machining unit to be removed and then reattached. This configuration allows machining to be performed continuously on the surface 18. Although not shown, the machining unit 14 may include one or more contacts arranged to engage with the surface 18 and be movable / slidable on it.

[0084] Referring now to Figure 3, the nozzle 22 for the electrochemical processing apparatus is illustrated in more detail.

[0085] The nozzle 22 is configured to discharge an electrolyte jet 24 toward the surface 18 of the workpiece. The nozzle 22 includes a body 32. The body 32 of the nozzle 22 is formed from a first body portion 34 and a second body portion 36 that are removably attachable. The first and second body portions 34 and 36 are provided with complementary surface-forming portions to enable their assembly.

[0086] The nozzle 22 is provided with a mounting configuration 38 for releasably attaching the first and second body portions 34, 36. The mounting configuration 38 is provided in the form of one or more holes extending through each of the first and second body portions 34, 36. A corresponding number of holes are provided for each of the first and second body portions 34, 36. The openings in the first and second body portions 34, 36 are aligned so that fasteners (not shown) can be received through them to attach the first and second body portions 34, 36 to each other. In the embodiment described, the mounting configuration 38 includes four holes in each of the first and second body portions 34, 36.

[0087] Referring now to Figure 4, the nozzle 22 includes an inlet port 40 and an outlet port 42. In the configuration described, the inlet port 40 is located on the first body portion 34. The outlet port 42 is defined by the distance between the first body portion 34 and the second body portion 36. The outlet port 42 is located on the surface of the body 32 of the nozzle 22, which is intended to be the lowest part during use.

[0088] The outlet port 42 provides an opening from which the electrolyte can be sprayed toward the surface 18 of the workpiece. In the embodiment described, the outlet port 42 is substantially rectangular. The outlet port 42 defines a width and depth. The nozzle opening size (i.e., width and depth) is controlled by the power supply's ability to generate a sufficient current density toward the surface 18 of the workpiece.

[0089] The width of the outlet port 42 may be in the range of 1 mm to 25 mm, for example, in the range of 5 mm to 20 mm. In one configuration, the width of the outlet port 42 may be approximately 10 mm. The depth of the outlet port 42 may be in the range of 0.01 mm to 1 mm, for example, in the range of 0.05 mm to 0.5 mm. In one configuration, the depth of the outlet port 42 may be approximately 0.2 mm.

[0090] The main body 32 includes an internal cavity 44 for receiving an electrolyte therein. When the first and second main body portions 34, 36 are attached to each other (i.e., when they are assembled), the cavity 44 is formed between them. The cavity 44 is formed by opposing concave regions in the first and second main body portions 34, 36.

[0091] The inlet port 40 is located upstream of the cavity 44 and is positioned to flow with it so that the electrolyte flows into the cavity 44 through the inlet port 40, thereby delivering the electrolyte to the cavity 44.

[0092] The outlet port 42 is located downstream of the cavity 44 and is positioned to flow with it so that the electrolyte flows from the cavity 44 to the outlet port 42. In this way, the inlet port 40, the cavity 44, and the outlet port 42 define the electrolyte flow path through the nozzle 22 (i.e., from the inlet port 40 through the cavity 44 to the outlet port 42). The outlet port 42 is provided so that, when in use, the nozzle 22 can discharge a jet of electrolyte toward the surface 18 of the workpiece.

[0093] The first and second main body portions 34 and 36 are configured and arranged to form a seal between them. The seal is positioned to substantially enclose the cavity 44. In the embodiment described, the seal is substantially U-shaped.

[0094] To form a seal, the first and second body portions 34, 36 include corresponding seal-forming portions. The first seal-forming portion 46 is provided on the first body portion 34. The second seal-forming portion 48 is provided on the second body portion 36. The first and second seal-forming portions 46, 48 are arranged to engage with each other when the first and second body portions 34, 36 are assembled.

[0095] The combination of seal-forming portions 46 and 48 forms a strong seal within the body 32 of the nozzle 22 to prevent / minimize electrolyte leakage. The mutual engagement of the first and second seal-forming portions 46 and 48 can form a labyrinth seal between them. In this way, the electrolyte is restricted from leaking by the meandering outlet path through which it must pass.

[0096] The first seal-forming portion 46 is provided in the form of a convex portion 46. The second seal-forming portion 48 is provided in the form of a recess (second seal-forming portion) 48 configured to receive the convex portion (first seal-forming portion) 46. In the alternative configuration, it should be clear that the first main body portion 34 may be provided with a concave seal-forming portion, and the second main body portion may be provided with a convex seal-forming portion. By providing the first and second seal-forming portions in the form of a recess (first seal-forming portion) 46 and a corresponding convex portion (second seal-forming portion) 48, the seal-forming portions are arranged in an aligned configuration, making it possible to facilitate the assembly of the first and second main body portions 34 and 36.

[0097] In some configurations, sealant may be applied between the first seal-forming portion 46 and the second seal-forming portion 48. The sealant can be retained within the groove. It should be found that the volume of sealant applied is less than or equal to the volume of the groove. This helps prevent the sealant from creating a gap between the first body portion 34 and the second body portion 36 (which would increase the size of the outlet port). The sealant may be a polyurethane sealant, a silicone sealant, or any other suitable type of sealant.

[0098] Referring here to Figure 5, the external profile of the nozzle 22 is illustrated. The body 32 defines an end face 50 surrounding the outlet port 42. In the illustrated configuration, the end face 50 is located on the outlet spout. The end face 50 is intended to face the workpiece surface 18 during use (i.e., it is located within the electrochemical processing apparatus 10). The cross-sectional area of ​​the end face 50, i.e., the end face 50 facing the surface 18, gives a specific area designed to optimize the potential interaction as seen from the surface 18. It should be seen that the angle of the end face 50 with respect to the surface 18 can be adjusted during use. As will be described in more detail below, the end face 50 is substantially non-planar, and the specific shape and configuration of the surface can be modified to suit the application.

[0099] Although not shown, the mounting configuration 38 provides a mounting configuration for attaching the nozzle 22 to the electrochemical processing apparatus 10, for example, to a mounting bracket (not shown) of the electrochemical processing apparatus 10. However, in alternative configurations, the mounting configuration may be independent of the mounting configuration 38.

[0100] The mounting configuration is such that the outer surface of the nozzle 22 abuts against the mounting bracket of the electrochemical processing apparatus 10 in order to mount the nozzle 22 to the apparatus 10. The electrochemical processing apparatus 10 is configured such that the nozzle 22 is positioned on the surface 18 at a predetermined angle (i.e., a non-perpendicular angle). The angle of the nozzle 22 with respect to the surface 18 of the workpiece may be in the range of 0 to 60 degrees, for example, in the range of 0 to 45 degrees.

[0101] In one configuration, the mounting bracket may be positioned at a predetermined angle (i.e., not perpendicular) to the surface 18, and the outer surface of the nozzle 22 that contacts the mounting bracket may be substantially parallel to the mounting bracket. Thus, the angle of the nozzle 22 can be defined by the angle of the mounting bracket with respect to the surface 18. In another configuration, the mounting bracket may be substantially perpendicular to the surface 18, and the outer surface of the nozzle 22 that contacts the bracket may be inclined with respect to the mounting bracket. Thus, the angle of the nozzle 22 can be defined by the angle of the outer surface of the nozzle 22 with respect to the mounting bracket. In yet another configuration, the mounting bracket may be positioned at a predetermined angle (i.e., not perpendicular) to the surface 18, and the outer surface of the nozzle 22 that contacts the mounting bracket may be inclined with respect to the mounting bracket. Thus, the angle of the nozzle 22 can be defined by a combination of the angle of the mounting bracket with respect to the surface 18 and the angle of the outer surface of the nozzle 22 with respect to the mounting bracket.

[0102] The first and second main body portions 34 and 36 define the opposing first and second outer surfaces 52 and 54 of the main body 32 of the nozzle 22. The first and second outer surfaces 52 and 54 define tapered or chamfered regions. In other words, the first and second outer surfaces 52 and 54 include the first and second chamfered regions 56 and 58.

[0103] The chamfered area is positioned at the top of the end face or outlet spout 50 during use, for example, directly above it. This lowest chamfered area deflects the liquid impacting it away from the electrolyte jet. Therefore, this chamfered area is positioned to minimize interference from the jet fluid, which results in a secondary processing effect due to reflection from the workpiece surface 18 and re-reflection from the nozzle 22 back to the surface 18.

[0104] Referring to Figure 6, the cavity 44 of the nozzle 22 is illustrated in more detail. As described above, the first and second main body portions 34, 36 define the cavity 44 when assembled. The cavity 44 is defined by first and second concave surfaces 60, 62 which define the first and second opposing cavity walls 64, 66.

[0105] The first and second opposing cavity walls 64 and 66 are tapered in the direction toward the outlet port 42. In other words, the first and second opposing cavity walls 64 and 66 are tapered to the minimum separation distance so as to define the throat portion 68 at a position separated from the outlet port 42.

[0106] The throat section 68 is positioned so as to be spaced apart from the outlet port 42. The first and second opposing cavity walls 64 and 66 extend along the direction from the throat section 68 toward the outlet port 42. In other words, the separation distance between the first opposing cavity wall 64 and the second opposing cavity wall 66 increases in the direction from the throat section 68 toward the outlet port 42.

[0107] Referring to Figures 7A and 7B, the first main body portion 34 and the second main body portion 36 of the nozzle 22 are shown, respectively. As described above, the cavity 44 is defined by first and second concave surfaces 60 and 62 that define the first and second opposing cavity walls 64 and 66. The first and second opposing cavity walls 64 and 66 each have lateral wall portions 70 and 72.

[0108] The lateral wall portions 70 and 72 define the side walls of the cavity 44 when the first and second main body portions 34 and 36 are attached to each other. The side walls of the cavity 44 defined by the lateral wall portions 70 and 72 are tapered in the direction toward the outlet port. In other words, the lateral wall portions (i.e., side walls) of the cavity 44 are tapered from the maximum distance away from the inlet port 40. The side walls of the cavity 44 are tapered down to the minimum distance away from the outlet port 42.

[0109] A predetermined region of the side wall of the cavity 44 adjacent to the outlet port 42, for example, the outlet region, is curved inward. In other words, a predetermined region of the lateral wall portions 70, 72 adjacent to the outlet port 42, for example, the outlet region, is curved inward. This region, i.e., the outlet region, is positioned directly upstream of the outlet port 42. In other words, the region, i.e., the outlet region, is positioned so that it is directly above the outlet port 42 when in use. This configuration of inwardly curved opposing side walls increases the flow of electrolyte at the lateral edges of the jet. This, on the other hand, helps to equalize the processing effect across the width of the electrolyte jet, otherwise the processing rate would be high in these lateral regions.

[0110] As shown above and in Figure 8, the main body 32 defines an end face 50 surrounding the outlet port 42. It can be seen that the end face 50 is formed by the distal, i.e., lower edges, of the first main body portion 34 and the second main body portion 36. The end face 50 of the main body 32 is substantially non-planar. The end face 50 is substantially symmetrical with respect to the central axis A of the nozzle. In the illustrated configuration, the end face 50 defines a substantially curved or inclined inward profile. In other words, the end face 50 defines at least partially curved or tapered lateral regions 74, 76. This helps to equalize the machining effect across the nozzle width, without which the machining rate would be higher at the edges of the jet due to flow effects and charge concentration. This deformation helps to counteract the effect of substantially increased resistance at the outer edges in the jet stream, which reduces mechanical efficiency, thereby equalizing the effect across the entire width of the jet. Each of the lateral regions 74 and 76 defines a continuous curved surface. In the illustrated configuration, the lateral regions 74 and 76 are convex, but in alternative configurations, they may be concave, or any other suitable shape may be defined.

[0111] The end face 50 (i.e., the lateral regions 74, 76) is curved or inclined toward the inner region 78 of the end face 50. In the illustrated configuration, the inner region 78 is a substantially flat or planar surface. The configuration of the end face 50 of this nozzle 22 gives a current density profile that is low at the edges (i.e., in the lateral regions 74, 76) and high in the central part (i.e., across the inner region 78). This makes it possible to obtain uniform depth removal of material across the end face 50 (i.e., across the workpiece channel).

[0112] Referring to Figures 9A, 9B, and 9C, alternative configurations for the nozzle end face are illustrated. Here, only the differences from nozzle 22 in Figures 3-8 are explained, and the same notation includes the initial letters "1", "2", and "3", respectively.

[0113] In the configuration of Figure 9A, the inner region 178 is curved. The inner region 178 (e.g., end face 50) is substantially symmetric with respect to the central axis A of the nozzle. The curved profile is inclined inward toward the center point of the nozzle 122. In the illustrated configuration, the inner region 178 defines a convex curve, but it should be understood that the curve may be concave in alternative embodiments. The end face 50 of the body 32 defines a continuous curved surface. In the configuration described, the curved end face 50 has a substantially constant radius of curvature. This configuration results in a curved profile of the surface that is deeper in the center and shallower on the sides, which can be beneficial, for example, in producing an increased surface area on the workpiece surface for cooling / heating or in creating channels for liquid retention. In alternative configurations, the curvature of the inner region 178 may differ from that of the lateral regions 174, 176, such that the inner region 178 has a larger or smaller radius of curvature. Furthermore, in alternative configurations, the lateral regions 174 and 176 may be curved as shown, while the inner region may be formed by a linear inclined / tapered surface. Although not shown, the end face 150 of the nozzle 122 may have a substantially planar or flat central region (i.e., on or near the central axis A of the nozzle 122).

[0114] In the configuration of Figure 9B, the lateral regions 274 and 276 are curved in a manner similar to that described above. In the embodiment described, the lateral regions 274 and 276 are curved convexly. The inner region 278 defines a linearly inclined profile. In other words, the inner region 278 is tapered (i.e., towards the center point of the end face 250). The inner region 278 (e.g., the end face 250) is substantially symmetric with respect to the central axis A of the nozzle 222. The end face 250 of the nozzle 222 includes a substantially planar or flat central region 280. In this configuration, the end face 250 of the nozzle 222 can be considered substantially trapezoidal in shape (i.e., in cross-section). This configuration results in a substantially triangular profile with a deep central surface and shallow lateral surfaces, which can be beneficial, for example, in creating an increased surface area on the workpiece surface for cooling / heating or creating channels for liquid retention. In the illustrated configuration, the flat or planar region 280 is positioned to be on or near the central axis A of the nozzle 222. In other words, the end face 250 defines a taper extending from the opposing side of the nozzle 222. The opposing sides of the taper intersect to define the central plane (central region) 280. The taper may be uniform (i.e., a straight edge or a curved edge). Alternatively, the taper may be non-uniform (i.e., including multiple regions inclined in different ways or a combination of convex and concave curved regions).

[0115] In the configuration of Figure 9C, the end face 350 of the nozzle 322 includes curved lateral regions 374, 376 as described with respect to Figures 8 and 9A. The substantially curved profile is inclined inward toward the center point of the nozzle 322 (i.e., inclined toward the central axis A of the nozzle 322). In this configuration, the end face 350 of the nozzle 322 can be considered to define the relief. The end face 350 is curved to define the concave region 382.

[0116] It should be seen that the concave region 382 may be formed by the inclined region of the end face or by any other suitable configuration. In Figure 9C, the concave region 382 is defined by a concave curve. The concave curve has a center point that intersects axis A. The end face 350 is substantially symmetric with respect to the central axis A.

[0117] It should be noted that the end face of the nozzle may be provided with any nonlinear configuration to machine different profiles onto the workpiece surface, if necessary. Examples of such additional profiles may be semicircular, hexagonal, oval, or elliptical.

[0118] While the nearly symmetrical end faces were explained with reference to the nozzles in Figures 1-9C, it should be clear that the lower edge can define an asymmetrical profile in some alternative configurations.

[0119] While these teachings have been described above with reference to one or more preferred embodiments, it should be apparent that various modifications or alterations can be made without departing from the scope defined in the subsequent claims.

Claims

1. A nozzle for an electrochemical processing apparatus, wherein the nozzle is An internal cavity for receiving electrolytes, An inlet port located upstream of the cavity and in which the electrolyte flows, for supplying the electrolyte to the cavity, An outlet port for discharging an electrolyte jet towards the workpiece surface during use, A main body comprising the following is defined: The outlet port is located downstream of the cavity and flows through it, defining a flow path from the inlet port through the cavity to the outlet port. The body comprises first and second body portions that can be removably attached, and when the first and second body portions are attached to each other, the first and second body portions form the cavity between them. The body comprises a nozzle having an end face that substantially encloses the outlet port and is intended to be positioned facing the surface of the workpiece when in use, the end face being substantially non-planar.

2. The nozzle according to claim 1, wherein the first and second main body portions are configured and arranged to form a seal between them that surrounds the cavity when the first and second main body portions are attached to each other.

3. The nozzle according to claim 2, wherein the first and second main body portions each comprise first and second seal-forming portions, and the first and second seal-forming portions each comprise a convex portion on the first or second main body portion and a corresponding recess on the other of the first or second main body portion, and sealant is optionally applied to the recess.

4. The nozzle according to claim 2 or 3, wherein the first and second main body portions are configured and arranged to form a labyrinth seal between them.

5. The nozzle according to any one of claims 1 to 4, wherein the first and second main bodies define first and second opposing cavity walls, and the first and second opposing cavity walls are tapered in the direction toward the outlet port.

6. The nozzle according to claim 5, wherein the first and second cavity walls are tapered to a minimum separation distance, defining a throat portion at a position separated from the outlet port.

7. The nozzle according to claim 6, wherein the first and second opposing cavity walls expand along a predetermined direction between the throat portion and the outlet port such that the separation distance between the first opposing cavity wall and the second opposing cavity wall increases.

8. The nozzle according to any one of claims 5 to 7, wherein each of the first and second opposing cavity walls is provided with a lateral wall portion that defines a cavity side wall when the first and second main body portions are attached to each other, and the cavity side wall is tapered in the direction toward the outlet port.

9. The nozzle according to claim 8, wherein the cavity side wall is tapered to the minimum separation distance close to the outlet port.

10. The nozzle according to claim 8 or 9, wherein the outlet region of the cavity side wall adjacent to the outlet port is curved inward.

11. The nozzle according to any one of claims 1 to 10, wherein the end face comprises a lateral region that is at least partially curved or tapered toward the inner region of the end face.

12. The nozzle according to claim 11, wherein the inner region is curved such that the end face defines a continuous curved surface.

13. The nozzle according to claim 11 or 12, wherein the inner region is substantially planar.

14. The nozzle according to claim 11 or 12, wherein the inner region is curved or inclined such that the inner region forms a concave region on the end face.

15. The nozzle according to any one of claims 1 to 14, wherein the body comprises an outlet spout surrounding the outlet port, and an external region of the body adjacent to the outlet spout, for example, above the outlet spout, is tapered or chamfered.

16. The mounting configuration further includes a mounting structure configured to allow the first and second main body portions to be removably attached, The nozzle according to any one of claims 1 to 15, wherein the mounting configuration forms a mounting configuration for attaching the nozzle to an electrochemical processing apparatus.

17. The nozzle according to any one of claims 1 to 16, wherein the outlet port is defined by the distance between the first body portion and the second body portion.

18. The nozzle according to any one of claims 1 to 17, wherein the outlet port is provided on the end face of the main body, which is intended to be at the bottom when in use.

19. The nozzle according to any one of claims 1 to 18, wherein the body is formed from a conductive material, and optionally the body is made of metal or a metal alloy, such as steel.

20. The nozzle according to any one of claims 1 to 19, wherein the outlet port has a width in the range of 1 mm to 25 mm, for example, in the range of 5 mm to 20 mm, and / or the outlet port has a depth in the range of 0.01 mm to 1 mm, for example, in the range of 0.05 mm to 0.5 mm.

21. An electrochemical processing apparatus for processing the surface of a workpiece, Electrolyte source, A nozzle according to any one of claims 1 to 20, wherein the nozzle is configured and arranged to receive an electrolyte from an electrolyte source through an inlet port and to discharge an electrolyte jet from an outlet port toward the surface of a workpiece when in use, An electrochemical processing apparatus equipped with the following features.

22. The electrochemical processing apparatus according to claim 21, wherein the electrochemical processing apparatus is configured to apply a charge to the nozzle and to the surface such that the nozzle and the surface of the workpiece define the first and second electrodes of the electrolytic cell when in use, and optionally the nozzle is positioned to be spaced apart from the surface of the workpiece when in use.

23. The electrochemical processing apparatus according to claim 21 or 22, further comprising contact electrodes configured and positioned to contact the surface of a workpiece during use and conduct an electric current thereto.

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