ECM-Rounded Nozzle Inlet for Cavitation-Stable Fluid Jets
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Solution Overview
Problem
Conventional methods for forming nozzle inlets in fluid nozzles for rotational equipment, such as gas turbine engines, are complex and costly, leading to increased manufacturing time and weight due to the need for precise machining and assembly, and often result in fluid cavitation issues that affect the stability and consistency of the fluid jet.
Innovation Solution
The use of an electro-chemical machining (ECM) system comprising a machining tool, power supply, and electrolyte supply assembly to form a nozzle inlet by removing the edge at the nozzle inlet and creating a fillet, which reduces fluid cavitation and improves jet consistency, involving a machining tool with a tapered profile and a flexible line to position the tool accurately within the nozzle body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining methods are used to form nozzle inlet, then manufacturing precision can be achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces conventional mechanical machining methods with electrochemical machining (ECM). The ECM system uses electrical current and electrolyte chemistry to remove material, eliminating the need for complex mechanical cutting tools, multiple machining operations, and precise tool positioning mechanisms. This substitution maintains manufacturing precision while significantly reducing device complexity and manufacturing cost.
Solution Approach 2:
The patent changes the fundamental parameter of material removal from mechanical force to electrochemical reaction. By controlling electrical current density, electrolyte composition, and voltage, the ECM process achieves precise nozzle inlet formation without the mechanical complexity of traditional machining. The rounded profile is created through controlled electrochemical dissolution rather than mechanical cutting.
2Ease of manufacture
If conventional machining methods are used to form nozzle inlet, then manufacturing can be completed, but manufacturing time increases
Solution Approach 1:
By replacing mechanical machining with electrochemical machining, the patent eliminates time-consuming operations such as multiple setup changes, tool adjustments, and manual finishing. The ECM process can be automated and runs continuously, significantly reducing total manufacturing time while simplifying the manufacturing procedure.
Solution Approach 2:
The ECM process allows for preliminary shaping of the nozzle inlet with the desired rounded profile in a single operation. The electrolyte and electrical parameters are pre-configured to achieve the target geometry, eliminating the need for subsequent finishing operations and reducing overall manufacturing time.
3Manufacturing precision
If conventional machining methods are used to form nozzle inlet, then manufacturing can be completed, but weight increases
Solution Approach 1:
The ECM process creates a cleaner, more precise nozzle inlet profile without the mechanical stresses and potential material deformations associated with conventional machining. This results in optimal material distribution and a lighter nozzle structure that maintains or improves manufacturing precision.
Solution Approach 2:
By controlling the electrochemical parameters (current density, voltage, electrolyte flow), the process achieves the precise rounded profile with minimal material removal. This optimized material removal pattern reduces unnecessary material and decreases nozzle weight while maintaining the required inlet profile accuracy.
4Ease of manufacture
If sharp edge is present at nozzle inlet, then manufacturing is simpler, but fluid cavitation occurs affecting jet stability
Solution Approach 1:
The ECM process inherently creates a rounded nozzle inlet profile by controlling the electrochemical dissolution rate. This rounded profile eliminates the sharp edge that causes fluid cavitation, thereby improving jet stability and reliability. The parameter control in ECM (current density distribution) naturally produces the beneficial rounded geometry without requiring additional finishing operations.
Solution Approach 2:
The electrochemical machining process provides better control over the nozzle inlet geometry compared to mechanical methods. The electrolyte flow and electrical field distribution create a uniform rounded profile that prevents cavitation, improving fluid dynamics and jet stability while maintaining manufacturing efficiency.
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 ECM process enables precise formation of a rounded nozzle inlet, reducing fluid cavitation and improving the consistency and targeting of the fluid jet, while simplifying the manufacturing process and reducing costs by eliminating the need for complex machining and assembly.
Implementation Method 1
an electro-chemical machining (ECM) assembly 94 installed on the nozzle body 76. The ECM assembly 94 may include a machining tool 96, a flexible line 92, an electrolyte supply assembly 100, and a power supply 98
Data Source
AI summary
A system for forming a nozzle inlet of a nozzle includes a nozzle body and an electro-chemical machining (ECM) assembly. The nozzle body includes an external surface. The nozzle body forms a nozzle orifice and a manifold passage. The nozzle orifice extends through the nozzle body between and to a nozzle inlet and a nozzle outlet. The nozzle inlet is disposed at the manifold passage. The nozzle outlet is disposed at the external surface. The ECM assembly is installed on the nozzle body. The ECM assembly includes a machining tool and a flexible line. The machining tool is disposed at the nozzle inlet. The flexible line is attached to the machining tool. The flexible line extends through the nozzle outlet from the machining tool to an exterior of the nozzle body.