Component Surface Finishing With Heated Fluid Convection
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Solution Overview
Problem
Existing finishing processes, such as electrochemical machining, often produce byproducts like salt that inhibit the finishing process and are not effective in accommodating varied surface finishing requirements, particularly in turbomachine components where low surface roughness is necessary.
Innovation Solution
A method involving immersing a component in a fluid and heating the fluid near the surface using a heat source, such as a laser, to create a convection current that carries away byproducts, thereby improving the finishing process and achieving the desired low surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrochemical machining is used to finish component surfaces, then material can be removed to achieve smooth surfaces, but byproducts such as salt are produced that inhibit the finishing process
Solution Approach 1:
The patent extracts the harmful salt byproducts from the electrolyte solution near the component surface by introducing a gas stream (inert or reactive gas) that flows across the surface to carry away the salt, preventing its accumulation and inhibition of the electrochemical machining process
Solution Approach 2:
The patent introduces a gas stream as an intermediary medium between the electrolyte solution and the component surface. This gas acts as a carrier to remove salt byproducts without directly contacting or interfering with the electrochemical machining process, thereby resolving the contradiction between material removal and byproduct inhibition
2Productivity
If conventional finishing processes are used, then byproducts accumulate on the surface, but the patent applies a gas stream to remove byproducts while maintaining the electrochemical process
Solution Approach 1:
The patent maintains continuous electrochemical machining operation by simultaneously introducing a continuous gas stream that removes salt byproducts in real-time, ensuring the finishing process continues without interruption or degradation from byproduct accumulation
Solution Approach 2:
The gas stream extracts salt byproducts from the electrolyte solution at the component surface during the ongoing electrochemical machining process, preventing the harmful accumulation that would otherwise stop or slow down the finishing operation
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
This approach effectively removes byproducts and enhances the finishing quality, achieving an average surface roughness of 1 to 5 micro-inches, suitable for turbomachine components, while reducing the need for excessive electrolyte and chemicals.
Implementation Method 1
heating fluid near the surface during the finishing process to create a convection current within the fluid that carries a byproduct of the finishing process away from the surface
Implementation Method 2
Electrochemical machining (or ECM) is an example finishing process that immerses at least a portion of a component in a fluid. Electrochemical machining processes use electrical energy to remove material. A tool serves as a cathode, and the component serves as an anode. During the process, the ECM tool is positioned very close to the workpiece and a low voltage, high amperage DC current is passed between the two via an electrolyte. A high-amperage, low-voltage current is then applied to dissolve and remove metal from the component.
Data Source
AI summary
An example component finishing method includes immersing a surface of a component within a fluid during a finishing process. The method heats fluid near the surface during the finishing to create a convection current within the fluid that carries a byproduct of the finishing away from the surface.