Robotic electrochemical machining system with end-functioning for machining freeform surfaces.

Abstract

The invention relates to an end-functioning device for machining free-form surfaces in a robotic electrochemical machining method that will enable the rapid and efficient production of parts used in the defense, aerospace, and medical sectors, where hard-to-machine metals with curves or bends in their surface geometry are used, by employing robotic electrochemical machining.

Description

1 TARIFF EQUIPPED WITH AN END FUNCTION FOR MACHINING FREE-FORM SURFACES. ROBOTIC ELECTROCHEMICAL PROCESSING SYSTEM The technical field to which the invention relates: The invention relates to the machining of a free form having curves or arcs in its surface geometry. Used in defense, aerospace and medical sectors where hard metals are employed. parts are processed quickly and efficiently using robotic electrochemical machining. an end-functioning machine to process free-form surfaces that will enable their production It relates to the robotic electrochemical processing system it possesses. State of the art: 10 Advances in science and technology have increased the need for difficult-to-process metals in their free form. It is increasing day by day. However, the conventional manufacturing of these types of surfaces Processing using these methods results in cost and time losses. These methods... For the production of these types of free-form surfaces on CNC machines, which are the most commonly used. At least 4 axes are required. Additionally, it should have high hot hardness (Inconel 718, 15). Tool wear is very common in materials such as TiAl, etc. However, it is very... Machining at high temperatures causes residual stresses on the surface. and causes changes in the mechanical properties of the material. In EDM, another method used, the workpiece and tool are powered by direct current. It is connected to the source. 20 from the workpiece in a non-electrically conductive liquid. The material is severed by sparks generated during a short circuit. During this process... the workpiece and the tool are exposed to sudden high temperatures and sudden cooling. It remains. Therefore, on the workpiece surface, as in CNC machines, it is no longer possible to... Stresses occur. However, a white (re-cast) appearance is observed on the workpiece surface. Layers are formed. In addition, the sparks and sudden temperature changes that occur affect the team's 25 It significantly reduces its lifespan. Another method used, the EKİ method, involves high-level free-form surfaces. It is considered an effective method for processing with efficiency. The EKİ method; regardless of the mechanical properties of the workpiece that has electrical conductivity 2 This makes manufacturing possible. During the process, residual stress and heat in the material are eliminated. No affected area is formed, thus no wear occurs on the cathode (tool) material. This does not happen. However, process control, low processing accuracy, etc. Due to its drawbacks, the use of the EKI method is not very widespread. This Different types of mathematical modeling are used in the literature to address these negative aspects. 5 It is possible to find these models, but since these models are performed under certain specific conditions, This situation is causing increased costs for the industry. The EKİ method only uses the anode. This process can be used based on the chemical reactions between the electrode and the cathode. This can be done regardless of the mechanical properties of the material to be processed. This demonstrates that, within this scope, it is frequently used in the space, aircraft, defense, and medical industries. Ti6Al4V and Inconel are used, but are difficult to process with conventional manufacturing methods. It can be used in machining special alloys such as 718. However, the tool has a mold. It is observed that the workpiece is moved in this manner. However, in the EKİ method, the workpiece is moved towards the workpiece. to perform precise processing using the opposite (mirror) geometry of the part It is not possible. 15 Robotic Electrochemical Processing (RECM) method; has high mobility. Using the EKİ method, one of the contactless processing methods with the aid of a robotic arm It is a newly developed integrated processing system. However, in this method, material processing Its speed is not as high as EKI. REKI has high mobility (six-axis). An electrode is mounted on the end of a robotic arm and the curve of a free-form surface is 20° EKI can be performed linearly by adhering to its vectors. Various proposals exist for machining free-form surfaces in the current state of the art. Although improvements have been made to the applications, these improvements are insufficient. For this purpose... Some of the applications related to the developed inventions are given below. The 25th issue of application number “TR2021 / 005817” is in the known state of the art. The invention is a robot that enables shaping of metals that are difficult to process. It relates to electrochemical processing systems, enabling the production of freeform surfaces at low cost. It describes the processing. Subject to application number “US7175752B2”, which is in the known state of the art. The invention is an electrochemical processing apparatus and method for processing a workpiece, 30 The device directs an electrolyte through a gap from the workpiece and then to an electrode. 3 a transmitted electrical power pulse is provided and this transmitted electrical power pulse It describes the machining process where the material is worn away from the workpiece when applied. In the current state of the art, shaping of free-form, difficult-to-machine metals is involved. It is taking advantage of the corrosion of the workpiece / processing part with the devices available in current technology. Its suitability, inability to perform three-dimensional scanning, inability to perform precise operations, the same 5 The ability of the tool to process only one free-form surface at a time depends on the processing depth. The increased amount of movement along the orbit, and consequently the longer processing time, It has negative aspects, such as the slow processing of the part. In conclusion, due to the negative aspects described above and the current solutions, the subject matter... Due to its shortcomings, an improvement in the relevant technical field is necessary. 10 It has been made. The purpose of the invention: The main purpose of the invention is to create free-standing structures with curves or shapes in their surface geometry. in the aerospace and medical industries where formed and difficult-to-process metals are used The key is the ability to process the parts used quickly and efficiently. 15 Another objective of the invention is to have a short tool travel and a large tool surface area. This results in increased processing speed and consequently shorter processing time. Another objective of the invention is to process two surfaces simultaneously. Thus, aircraft engines... free-form surfaces with both concave and convex shapes, as in the panels, simultaneously It can be processed. 20 Another objective of the invention is the direct spraying of the electrolyte onto the workpiece. Thus, electrolyte-induced corrosive effects on robotic arms and other equipment and measures taken to address them Measures are being reduced and system installation costs are decreasing. Another aim of the invention is to be an end-functioning device with its own movement mechanism. Thus, the team movement is performed by the end function. 25 Another objective of the invention is to allow the tool geometry to vary depending on the workpiece. Thus, workpieces with different geometries can be produced more precisely. 4 Explanation of the figures: FIGURE -1; An end-processing machine for machining free-form surfaces, which is the subject of the invention. This is a drawing that shows the appearance of the robotic electrochemical processing system. FIGURE 2; An end-processing machine for machining free-form surfaces, which is the subject of the invention. The robotic electrochemical machining system has 5 robotic arms, end functioners and workpieces. It is a drawing that gives an isometric view. FIGURE -3; An end-processing machine for machining free-form surfaces, which is the subject of the invention. robotic electrochemical machining system with end function and isometric view of workpiece It is a drawing that gives the image. FIGURE -4; A 10-bit end-processor for machining free-form surfaces, which is the subject of the invention. front (a) and bottom (b) of the end function of the robotic electrochemical processing system It is a drawing that gives an image of its appearance. Reference numbers: 1. REKI end function Team 2, 15 3. Jaw 4. Electrolyte injector 5. Robotic arm 6. Power supply 7. 3D scanner 20 8. PLC 9. Flowmeter 10. Frequency inverter 11. Thermal camera 12th Gear 13. Screw shaft 14. Sliding shaft 15. Engine 5 16. Workpiece 17. Computer 18. Pump 19. Electrolyte tank Description of the invention: 10 The invention relates to the machining of a free form having a curve or curves in its surface geometry. Defense using hard metals (special alloys such as Ti6Al4V and Inconel 718), Robotic electrochemical machining of parts used in the aerospace and medical industries. freeform that will allow for quick and efficient production using the workbench Robotic electrochemical machining with an end-functioning device for processing surfaces 15 It is related to the (REKI) system. The invention is the movement of the robotic arm (5) used in the REKI system in a direction parallel to the end of the arm. It is formed by placing a set (2) that can be realized. Thus, it has two faces. The tool (2) moves towards the workpiece (16) at the same time and two different freeform The surface can be processed quickly and simultaneously. 20 The invention describes a robot with an end-functioning device for machining free-form surfaces. electrochemical machining (ECM) system, tools (2) that shape the workpiece (16), the jaw (3) that holds the tools (2) and enables their movement, the workpiece (16) and the tool (2) electrolyte (16) to carry out chemical reactions between the workpiece electrolyte sprayer (4) that sprays electrolyte from tank (19), tool (2) and work 25 part (16) of the direct current power supply (6) which provides current and voltage between the sets 6 (2) the motor (15) that moves the (3) holding jaws onto the (16) workpiece, the gears (12), REKI end function (1), located on the screw shaft (13) and sliding shaft (14), robot arm (5), 3D scanner (7) which detects the location of the workpiece (16), analog and digital signals PLC (8) coordinating, flowmeter (9) detecting the amount of electrolyte, electrolyte pump (18) that provides the transfer, frequency inverter 5 that changes the power of the pump (18) (10) and the thermal camera (11) which detects the temperature, where data about the whole system is collected It consists of a computer (17) and an electrolyte tank (19) in which the electrolyte is collected. The invention improves efficiency in machining free-form parts for REKI systems. It increases. First, the operating parameters of the system are determined by the operator and Ranges are determined. These are; Voltage, Electrolyte flow rate, tool (2) and workpiece (16) 10 The initial gap between the tools is the feed rate of the tool (2). In the REKI system, the work The position of part (16) is determined with the help of a 3D scanner (7) and the robot arm (5) by communicating with PLC (8) at a certain distance from the workpiece (16) is positioned. After the robot arm (5) is positioned, the REKI end function (1) is positioned. With the help of the motor (15), the jaws (3) holding the tools (2) move towards the workpiece (16). The moving jaws (3) work for the amount of clearance determined by the operator. It approaches part (16). After the jaws (3) are positioned, first electrolyte electrolyte transfer from the sprayer (4) between the workpiece (16) and the tool (2) This is done by switching on the Direct Current (DC) power supply (6) and chemical The reactions are initiated. Current and voltage values ​​are displayed on the screen. When reading is started, the jaws located in the REKI end functioner (1) with the help of PLC (8) (3) moves towards the workpiece (16) at the specified speed in the REKI system. Flow-temperature changes are monitored with the thermal camera (11) and flowmeter (9) located. When the machining of the workpiece (16) is completed, it is powered from the DA power supply (6) Frequency inverter (10) 25 which stops the voltage transfer and enables the electrolyte to be delivered. The jaws (3) are closed. The robotic arm (5) is brought to its initial position and the safe zone is closed. It is being transmitted. Thanks to the REKI end function (1) provided by the invention, the processing speed of the REKI system is increased. Depending on the size of the part (16), it increases 5-50 times. REKI end processor (1) is powered by a motor (15) placed in its upper chamber and gears (12) 30 The movement is transmitted to a screw shaft (13) with right and left teeth. On this screw shaft (13) As the rotational movement occurs, the jaws (3) move closer to each other or 7 It is moving away. The jaw (3) slides so that the movement can be performed comfortably. Teflon drivers are placed between the spindle (14) and the jaw (3). Robotics with an end function for machining freeform surfaces Electrochemical processing (ECP) system operating procedure steps; - Placement of the workpiece (16) into the vise by the operator, 5 - Determining the position of the workpiece (16) with the 3D scanner (7), - The position of the workpiece (16) and the appropriate communication protocol of the robot arm (5) learning through application, - The robot arm (5) can move a certain distance depending on the position of the workpiece (16). positioning, 10 - REKI end function tools (1) at the end of the robot arm (5) from the workpiece (2) (16) positioned at a certain distance, - The relevant parameters (Voltage, electrolyte flow rate, tool (2) by the operator (determining the rate of progress, etc.) - The specified team (2) advance speed is determined by PLC (8) with the help of specific communication 15 Transmission to the REKI end functioner (1) in accordance with the protocols, - According to the information received, the motor (15) located in the REKI end functioner (1) moving - Transmission of motion to the right and left toothed screw shaft (13) via gears (12), - The jaws (3) mounted on the screw shaft (13) and the mounting of the jaws (3) were previously 20 the (2) teams that have been formed move towards each other, - Electrolyte sprayer (4) on the workpiece (16) during the movement of the tools (2) electrolyte injection, - Check the following parameters during the process: The current and voltage values ​​in the DC power supply (6) are 25 8 those temperature values, Flow rate. Conditions that must be met when the invention and the workpiece (16) are produced; - Electrolyte temperature: 20-30 °C - Electrolyte flow rate: 1-20 lt / min. 5 - Electrolyte pressure must be at least 1 bar. - The position of the workpiece (16) must be determined with a maximum error of 10 µm, - The repeatability of the robot arm (5) should not exceed 20 µm, - Analog signal output of thermal camera (11), flowmeter (9) and DC power supply (6) 10 to be able to give - The sensitivity of the movement of the tool (2) should not exceed 5 µm. - When there is contact between the tool (2) holding workpiece (16) and the tool (2) for 1 second being able to remove the team (2) from it, - The tool (2) can be moved at a speed of at least 0.1 mm / min. The tool set (2) is resistant to rust. 15 The invention is based on the fact that in the REKI end function (1) the workpiece (16) is completely enclosed and The electrolyte is delivered directly to the workpiece (16) surface without splashing. Thus, it is necessary to protect the robot arm (5) and other equipment against corrosion. Measures are being reduced and the costs required for system installation are decreasing. The invention allows two surfaces to be processed simultaneously. Thus, it can process multiple surfaces (inner 20 (16) a workpiece (convex and convex) faster and more precisely This allows for efficient processing. This results in shorter production times and reduced costs. It is falling. 9 In the invention, the tool (2) geometry differs from the workpiece (16) geometry. Thus, more precise cutting of workpieces with different geometries (16) It can be produced. The REKI end functioner (1) presented in the invention is brought to the workpiece (16) by robotic arm (5). The movement of the team (2) is performed by the REKI end function (1). Thus, 5 There is a REKI end functioner (1) with its own movement mechanism. This REKI end The tools (2) are mounted on the jaws (3) located in the functioner (1) and the REKI end functioner (1) The robot arm (5) moves with the help of its own motor (15) movement mechanism. workpiece by using more tool (2) surfaces in a shorter distance without being made (16) can be processed. Thus, it offers a faster and more precise processing opportunity. 10 The movement of the tool (2) is achieved by linear movement towards the workpiece (16). In addition, the tool (2) surface is used to be equal to or larger than the workpiece (16). Because of the short movement of the tool (2) and the large surface area of ​​the tool (2), machining The speed is increasing, and consequently, the processing time is decreasing. To ensure the movement and geometric variety of the team (2) with the invention, a REKI 15 The end functioner (1) is provided. The tool (2) is placed in this REKI end functioner (1) Due to the size of its geometry, it can simultaneously work on more than one workpiece (16) region Current can be transmitted, and consequently, the processing speed increases according to Faraday's laws. It also shows that aircraft engine panels have concave and convex freeform shapes. Formed surfaces can be processed simultaneously. Thus, the processing speed is currently 20 Parts can be processed 5-50 times faster than with the REKI system. With this... In this way, electrolyte-related corrosive effects and measures to address them are reduced, and The system's installation costs are being reduced.

Claims

REQUESTS 1. Robotics with an end function for machining freeform surfaces. It is an electrochemical processing system; its characteristic feature is: - tools (2) that shape the workpiece (16), tools (2) that hold and move the jaw (3) that provides chemical 5 between the workpiece (16) and the tool (2) to carry out the reactions from the electrolyte tank (19) to the workpiece (16) electrolyte sprayer (4) spraying the incoming electrolyte, tool (2) and workpiece (16) to the direct current power supply (6) which provides current and voltage between (16), motor that moves the jaws (3) holding the tools (2) onto the workpiece (16) (15) to the gears (12) that transmit the movement of the motor (15) to the screw shaft (13), the gears 10 (12) with the movement transmitted by the jaws (3) and the jaws (3) mounted on the jaws screw shaft(13) which enables the tools (2) to move towards each other and Enables the comfortable movement of the jaw (3) and the jaw (3) REKI has a sliding shaft (14) with Teflon drives placed between it. end function (1), 15 - located at a certain distance depending on the position of the workpiece (16), having a REKI end function (1) at its end and these REKI end function (1) and their sets (2) robot arm (5) that enables it to stop at a certain distance from the workpiece, - 3D scanner (7) which detects the location of the workpiece (16), - PLC (8), which coordinates analog and digital signals, 20 - flowmeter (9) that detects the amount of electrolyte, - pump that provides electrolyte transfer (18), - frequency inverter (10) which changes the power of the pump (18), - electrolyte tank in which the electrolyte is collected (19), - computer on which all system data is collected (17), 25 - It includes a thermal camera (11) that detects the temperature.

2. To be able to machine freeform surfaces according to claim 1, it must have an end function. It is a robotic electrochemical processing system, the feature of which is that the workpiece (16) is completely by closing the system, the electrolyte is delivered directly to the workpiece (16) surface. It contains an electrolyte sprayer (4) which prevents it from being exposed to corrosive effects. 30 3. To be able to machine freeform surfaces according to claim 1, it must have an end function. It is a robotic electrochemical processing system, characterized by having multiple surfaces. 11 capable of machining both surfaces of the workpiece (16) at the same time and shortening the production time REKI includes end function (1).

4. Having an end function for machining freeform surfaces according to claim 1. It is a robotic electrochemical processing system, and its feature is; the geometry of the workpiece (16). It includes a jaw (3) that allows different sets (2) to be used by attaching them. 5 5. To be able to machine freeform surfaces according to claim 1, it must have an end function. It is a robotic electrochemical processing system, and its feature is that the REKI end-functioning (1) works. It includes a robotic arm (5) that enables it to move towards part (16).

6. Having an end function for machining freeform surfaces according to claim 1. It is a robotic electrochemical processing system, and its feature is that the robot arm (5) works with 10 workpieces. (16) remaining fixed at a certain distance from the workpiece (16) at a certain distance team (2) movement and thanks to this movement REKI system 5-50 REKI end function (1) which enables workpiece (16) to be machined much faster. It contains the motor (5) on it.