Internal Passage Electrode Removal for ECM Surface Smoothing

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Solution Overview

Problem

Existing methods for improving the surface finish of interior surfaces of workpieces, such as additive manufacturing and electrochemical machining, face challenges with complex geometries and the difficulty of accessing and removing electrodes from internal passages without causing thermal or mechanical stress.

Innovation Solution

A system and method involving an electrode located within the internal passage and electrically isolated from the workpiece, with an electrolyte supply and power supply to smooth the interior surface using electrochemical machining, and a remover to completely extract the electrode after the process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional ECM process is used to smooth interior surfaces, then surface finish is improved, but the cathode cannot access complex internal passages

Engineering Contradiction:

Improvesurface finishVSAvoidaccess to internal passage

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The cathode is divided into multiple segments that can be independently positioned and oriented. Each segment can be adjusted to navigate complex internal passages, allowing the cathode to access difficult-to-reach interior surfaces while maintaining effective ECM processing capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cathode is designed with dynamic positioning capabilities, allowing it to be moved and repositioned within the workpiece during the ECM process. This dynamic adjustment enables the cathode to access complex internal passages and adapt to varying geometric configurations.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If conventional ECM process is used, then surface finish is improved, but the cathode cannot be easily removed from internal passages

Engineering Contradiction:

Improvesurface finishVSAvoidremoval of cathode

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The cathode design incorporates extraction features that facilitate easy removal from the internal passages after the ECM process. These features may include tapered sections, magnetic coupling mechanisms, or other extraction aids that allow the cathode to be cleanly removed without damaging the workpiece or requiring complex disassembly procedures.

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If mechanical methods are used to smooth interior surfaces, then surface finish is improved, but thermal or mechanical stress is transferred to the workpiece

Engineering Contradiction:

Improvesurface finishVSAvoidthermal or mechanical stress

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical machining methods with electrochemical machining. Instead of using mechanical contact between cutting tools and the workpiece, the ECM process uses electrochemical reactions to remove material. This substitution eliminates mechanical stress and thermal effects associated with conventional machining, providing stress-free surface finishing for interior passages.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Effectively smooths interior surfaces without thermal or mechanical stress, enabling high-quality surface finishes in complex geometries and facilitating the removal of the electrode from internal passages.

Implementation Method 1

The power supply is configured for applying a voltage between the electrode and the workpiece to facilitate smoothing the interior surface

Methodology Applied

Scientific EffectElectrochemical machining: Electrolysis

Implementation Method 2

The electrolyte supply is configured for circulating an electrolyte in a gap between the electrode and the workpiece

Methodology Applied

Scientific EffectElectrolyte circulation: Electrolyte

Data Source

PatentUS11745279B2System and method for machining workpiece and article machined therefrom

Publication Date: 2023.09.05 GENERAL ELECTRIC CO

AI summary

A system is configured for machining a workpiece (100), the workpiece includes an interior surface (110) that defines an internal passage (112). The system includes an electrode (116) located within the internal passage and electrically isolated from the workpiece, an electrolyte supply, a power supply, and a remover. The electrolyte supply is configured for circulating an electrolyte in a gap between the electrode and the workpiece. The power supply is configured for applying a voltage between the electrode and the workpiece to facilitate smoothing the interior surface. The remover is configured for completely removing the electrode from within the internal passage after smoothing the interior surface.