Electrochemical Machining Machine with Inverted Workpiece Rotation
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Solution Overview
Problem
Existing electrochemical metalworking (ECM) machines face challenges in achieving high feed and positioning accuracy due to long power flow distances and low machine rigidity, which affect the precision and efficiency of metal removal.
Innovation Solution
A compact machine tool design featuring a solid base body made of reaction resin concrete with strategically arranged guides and oscillating mechanisms, reducing power flow distances and enhancing machine rigidity, utilizing 10 numerically controlled axes for precise movement and tool positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional ECM machine designs with multiple movable axes are used, then flexibility and adaptability are improved, but power flow distances become excessively long and machine rigidity deteriorates
Solution Approach 1:
Instead of moving the tool relative to a stationary workpiece holder, the patent inverts the arrangement by making the workpiece rotate on a turntable while the tool remains relatively stationary on a fixed carriage. This inversion dramatically shortens the power flow path from meters to centimeters, resolving the contradiction between flexibility and power flow distance.
Solution Approach 2:
The patent introduces rotational movement around a vertical axis (turntable) as an additional dimension of motion, replacing the need for complex linear movements in multiple axes. This dimensional change achieves machining flexibility through rotation rather than through long linear travel distances.
2Adaptability or versatility
If traditional ECM machine designs with multiple movable axes are used, then flexibility and adaptability are improved, but machine rigidity deteriorates
Solution Approach 1:
By inverting the motion system so that the workpiece rotates rather than the tool moving along long axes, the patent creates a compact structure with short support spans. This dramatically improves machine rigidity while maintaining flexibility through the rotational degree of freedom.
Solution Approach 2:
The patent segments the motion functions: the turntable provides rotational positioning, the fixed carriage provides stable tool support, and the electrolyte circulation system provides flushing. This segmentation allows each component to be optimized for its specific function, improving overall rigidity.
3Ease of operation
If traditional ECM machine designs with long power flow distances are used, then tool accessibility is improved, but feed and positioning accuracy deteriorates
Solution Approach 1:
The inverted configuration places the tool in a fixed, easily accessible position on the carriage while the workpiece rotates into position. This maintains full tool accessibility while achieving sub-millimeter positioning accuracy through the compact arrangement and precise rotational control.
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 compact design with optimized axis configuration improves positioning accuracy and machine rigidity, ensuring efficient metal removal with reduced power flow distances and increased precision.
Implementation Method 1
In the working gap between the two electrodes, an electrolyte solution, e.g. sodium chloride or sodium nitrate, transports the charge.
Implementation Method 2
An oscillating working stroke is superimposed on the infeed movement via the oscillator unit 14, as a result of which the tool 15 is moved alternately parallel to the X-guide at a frequency of the order of 50 Hz.
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a machine for electrochemical metal machining, wherein metal is removed by electrolytic dissolution of the workpiece (10), comprising a frame (1), with a work holder (19), wherein a workpiece (10) is mounted in the work holder (19) in such a way that it can be rotationally driven under numerical control about a vertical spindle axis (6) and a horizontal axis of rotation (9), with at least one tool (15), which can be infed to the workpiece (10), wherein the workpiece (10) is positively poled as an anode and the tool (15) is negatively poled as a cathode, wherein the work holder (19) is guided movably in a controlled manner in relation to the frame (1) in a horizontal direction on the horizontal slide (4) along Y guides (3) and in a vertical direction with the spindle (5) along the Z guide (16), and the tool (15) can be moved in a horizontal direction on the infeed slide (12) along the X guide (11) on the frame (1).