Centrifugal EDM Electrodes for Internal Ring Groove Machining
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Solution Overview
Problem
Conventional machining methods for ring grooves on internal rotation surfaces of workpieces are time-consuming and result in uneven stress distribution and vibration, leading to poor surface roughness due to the asymmetry of non-centrosymmetric holes, which affects machining quality.
Innovation Solution
An electrical machining apparatus with a rotatable shaft and symmetrically disposed electrodes that move under centrifugal force to generate even force distribution and simultaneous machining, using EDM, ECM, or ECDM processes to create ring grooves with improved surface flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional machining methods (lathe or miller) are used to machine ring grooves on internal rotation surfaces, then the machining process can be performed, but the machining time is excessive and the required machining tool rigidity is high
Solution Approach 1:
The patent replaces conventional mechanical machining methods (lathe or miller) with electrical discharge machining (EDM). The EDM process uses electrical discharges to erode material instead of mechanical cutting, eliminating the need for high-rigidity tools and reducing machining time significantly while achieving the same ring groove machining objective
2Manufacturing precision
If conventional cutting tools are used on non-centrosymmetric holes with asymmetric end faces, then machining can be performed, but uneven stress distribution causes vibration and poor surface roughness
Solution Approach 1:
The patent replaces mechanical cutting tools with electrical discharge machining electrodes. The EDM process eliminates mechanical contact between the tool and workpiece, thereby eliminating the uneven stress distribution and vibration that occur with asymmetric end faces in non-centrosymmetric holes, resulting in improved surface roughness and machining quality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus achieves efficient and cost-effective machining with improved surface flatness and reduced vibration, allowing for precise control of groove size and distribution, enhancing machining quality.
Implementation Method 1
When the rotatable shaft is rotated, the at least two electrodes are pushed towards a workpiece under an action of the centrifugal force
Implementation Method 2
the at least two electrodes are pushed towards a workpiece under an action of the centrifugal force so as to remove a portion of a material of the workpiece
Data Source
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AI summary
The present invention discloses an apparatus for electrical machining, where the apparatus includes a rotatable shaft and an electrode for electrical machining, and the electrode may be movably connected to the rotatable shaft. When the rotatable shaft is rotated, the electrode rotates together with the rotatable shaft and moves relative to the rotatable shaft under an action of centrifugal force, and a moving distance of the electrode is controlled based on a rotary speed of the rotatable shaft. The present invention further discloses a method for electrical machining, where the method includes: movably connecting an electrode to a rotatable shaft; inserting the rotatable shaft into a hole in a workpiece, and keeping a gap between the electrode and the workpiece, where the hole has a first diameter; powering on the electrode and the workpiece; rotating the rotatable shaft in the hole to generate centrifugal force; and pushing the electrode relative to the rotatable shaft towards the workpiece under an action of the centrifugal force to remove a portion of a material of the hole, so that the hole has a second diameter, where the second diameter is greater than the first diameter. The apparatus for electrical machining and the method for electrical machining according to the present invention are simple, easy to implement, and cost effective.