Electrochemical Drilling Tool for Variable Geometry Bore Holes

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Solution Overview

Problem

Existing electrochemical machining (ECM) processes, such as shaped-tube ECM, are limited in forming cooling channels with variable geometry in turbine blades due to the fixed orientation of electrode tips and rigidity of drilling tubes, restricting the geometric complexity of cooling channels.

Innovation Solution

An electrochemical machining system with a drilling tool featuring multiple electrode patches and a flexible guide member, coupled with an inspection device and controller, allows for real-time feedback and corrective actions to form continuous, variable-geometry bore holes within conductive work pieces by advancing the drilling tool along a tool path with positional adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a fixed orientation electrode tip and rigid drilling tube are used in STEM, then the machining process is simple and reliable, but the geometry of cooling channels is limited to straight channels with high aspect ratios

Engineering Contradiction:

Improvegeometry of cooling channelsVSAvoiddrilling tool structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The electrode tip is divided into multiple electrode patches arranged in different orientations around the drilling tube. Each electrode patch can independently remove material in its specific direction, enabling the formation of complex variable-geometry bore holes with curves and branches without changing the overall tool structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The drilling tool transitions from a fixed rigid structure to a dynamically controllable system where multiple electrode patches can be selectively activated or deactivated based on the required tool path geometry, allowing adaptive machining of complex cooling channel configurations.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If real-time inspection and corrective actions are implemented, then the accuracy of bore hole formation is improved, but the system complexity and processing time increase

Engineering Contradiction:

Improveposition accuracy of drilling toolVSAvoidcontrol system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

An inspection device continuously monitors the position of the drilling tool along the tool path in real-time. The controller compares the actual position with the theoretical position and determines position errors, enabling real-time feedback control to maintain machining accuracy.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system replaces complex mechanical positioning mechanisms with an electronic control system that uses inspection data and computational algorithms to achieve precise tool path following through software-based correction rather than mechanical adjustment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If multiple electrode patches are used to form variable-geometry bore holes, then the versatility of cooling channel formation is improved, but the device complexity and control difficulty increase

Engineering Contradiction:

Improvevariable-geometry bore hole formationVSAvoidcontrol of drilling tool

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The drilling tool with multiple electrode patches serves multiple functions: it can machine straight channels, curved channels, and branched cooling channels using the same tool structure by selectively activating different electrode patches, eliminating the need for multiple specialized tools.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system controls the machining process by changing the electrical parameters (activating or deactivating specific electrode patches) rather than changing mechanical parameters, allowing flexible adaptation to different cooling channel geometries through software control.

Inventive Principle:

Principle #35Parameter changes

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

Enables the precise and efficient formation of complex, variable-geometry bore holes within conductive work pieces, ensuring accurate alignment and material removal, thereby enhancing the machining process's autonomy, accuracy, and efficiency.

Implementation Method 1

material is oxidized and removed from the conductive work piece near the leading edge of the drilling tube

Methodology Applied

Scientific EffectElectrochemical oxidation: Oxidation

Data Source

PatentUS9943921B2Electrochemical machining system and method of machining a conductive work piece

Publication Date: 2018.04.17 GE INFRASTRUCTURE TECH LLC

AI summary

An electrochemical machining system for machining a conductive work piece is provided. The system includes a drilling tool configured to remove material from the conductive work piece. The drilling tool is configured to advance within the conductive work piece along a tool path to form a bore hole having a variable geometry that extends through the conductive work piece when the material is removed therefrom. The system further includes an inspection device configured to determine a position of the drilling tool along the tool path, and a controller configured to communicate with the inspection device. The controller is further configured to compare the tool path to a nominal tool path, and determine a position error of said drilling tool, the position error defined by a difference between the tool path and the nominal tool path.