Electrochemical Machining With In-Situ Electrolyte Jet Cleaning
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Solution Overview
Problem
Conventional electrochemical machining processes require separate and labor-intensive steps for removing the residue layer formed on components, increasing manufacturing effort and expense due to the hardness of the dried crust.
Innovation Solution
Integrate a cleaning device within the manufacturing device to jet-spray an electrolyte solution directly on the component for residue removal during or immediately after machining, allowing simultaneous electrochemical machining and cleaning without the need for additional setup or shot peening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrochemical machining is performed using conventional methods, then material removal and surface machining are achieved, but a residue layer forms on the component that requires separate shot peening for removal
Solution Approach 1:
The patent combines the electrochemical machining process and the cleaning process into a single integrated device. The machining device and cleaning device share common components including the component holder, electrolyte supply system, and housing structure. This merging eliminates the need for separate shot peening operations and reduces the number of handling steps required to remove the residue layer.
Solution Approach 2:
The manufacturing device is designed to perform multiple functions: electrochemical machining, electrolyte circulation, and residue layer removal. The same electrolyte solution used during machining is reused for cleaning, and the device can switch between machining mode and cleaning mode without requiring component removal or additional equipment.
2Ease of operation
If the residue layer is allowed to dry and harden, then it becomes easier to handle the component, but the residue layer becomes difficult to remove requiring tedious shot peening
Solution Approach 1:
The cleaning operation is performed immediately after machining while the residue layer is still in its fresh, soft state. The device transitions directly from machining mode to cleaning mode without allowing the residue layer to dry and harden, thereby eliminating the need for forceful removal methods like shot peening.
Solution Approach 2:
The residue layer, which is initially a harmful byproduct requiring removal, is actually beneficial during the cleaning process. The fresh residue layer softens upon contact with the electrolyte solution during cleaning, making it easier to remove. The electrolyte penetrates and softens the residue layer, converting the cleaning challenge into an easier process.
3Productivity
If the component is removed from the manufacturing device for separate cleaning, then the machining process is complete, but additional handling and processing time is required
Solution Approach 1:
The machining and cleaning operations are merged into a single continuous process within the same device. The component remains in the manufacturing device throughout both operations, eliminating the need for removal and repositioning. The electrolyte circulation system continues to operate during cleaning, maintaining continuous fluid flow without interruption.
Solution Approach 2:
The electrolyte circulation and component processing continue without interruption from machining to cleaning. The device maintains continuous operation by switching modes rather than stopping, and the component remains in position throughout the entire process, eliminating idle time and handling delays.
4Reliability
If shot peening is used to remove the residue layer, then complete removal is achieved, but the process is tedious and increases manufacturing expense
Solution Approach 1:
The mechanical shot peening process is replaced with an electrochemical cleaning process. Instead of using mechanical projectiles to impact and remove the residue layer, the patent uses electrolyte solution circulation and jet spraying to chemically and physically remove the residue layer in a gentler, more efficient manner.
Solution Approach 2:
The cleaning process utilizes hydraulic principles by circulating electrolyte solution through the gap between the machining device and component, and by using jet nozzles to spray electrolyte directly onto the residue layer. This hydraulic cleaning method replaces the need for mechanical shot peening equipment.
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
Reduces manufacturing effort and expense by enabling in-situ cleaning of the residue layer while it is still fluid, avoiding the complexity of shot peening and reducing the need for additional equipment and logistics.
Implementation Method 1
alloy constituents of the component are released by means of electrolysis and dissolve in solution as electrolyte
Implementation Method 2
jet-spraying the electrolyte solution on the component in order to remove the residue layer formed on the component
Data Source
AI summary
The invention relates to a manufacturing device for the electrochemical machining of a component, in particular a turbine component, wherein the manufacturing device comprises at least one machining device, which is set up to remove material of the component in accordance with a predetermined electrochemical machining method. It is provided that the manufacturing device comprises at least one cleaning device, which is set up to spray jets of the electrolyte solution onto the component in accordance with a predetermined jet-spraying method in order to remove a residue layer formed on the component during the predetermined electrochemical machining method.