ECM Nozzle Inlet Fillet Formation for Consistent 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 complex machining and assembly processes.
Innovation Solution
The use of an electro-chemical machining (ECM) system comprising a machining tool, power supply, flexible line, and electrolyte supply assembly to form a nozzle inlet by removing the edge at the nozzle inlet and creating a fillet, reducing fluid cavitation and improving jet consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining methods are used to form nozzle inlets, 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 and multi-step machining operations. This substitution maintains manufacturing precision while significantly reducing device complexity and machining time.
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 system achieves precise nozzle inlet formation without the complexity of mechanical tooling. This parameter change enables simpler equipment while maintaining or improving manufacturing precision.
2Manufacturing precision
If conventional machining methods are used to form nozzle inlets, then nozzle inlet geometry can be formed, but manufacturing time increases
Solution Approach 1:
The ECM process replaces time-consuming mechanical machining operations with a faster electrochemical material removal process. The chemical reaction occurs continuously as the tool passes through the workpiece, eliminating the need for multiple passes, tool changes, and complex setup procedures required by conventional machining, thereby reducing manufacturing time while maintaining geometric precision.
Solution Approach 2:
The ECM process enables continuous material removal throughout the machining operation. The electrolyte flows continuously through the gap between the tool and workpiece, allowing uninterrupted electrochemical reaction and material removal. This continuity eliminates the stop-start nature of conventional machining, significantly reducing total manufacturing time while maintaining precise nozzle inlet geometry.
3Manufacturing precision
If complex machining processes are used to form nozzle inlets, then precise nozzle inlet formation can be achieved, but weight of the nozzle increases
Solution Approach 1:
The ECM process removes material more precisely and efficiently than conventional machining, allowing for optimized nozzle inlet geometry with minimal material. The electrochemical process enables cleaner cuts and better surface finish without requiring additional material for compensation or reinforcement, thereby reducing overall nozzle weight while maintaining formation precision.
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 and efficient formation of nozzle inlets with a mirror-quality surface finish, reducing manufacturing complexity and cost, while enhancing fluid jet consistency and targeting.
Implementation Method 1
electro-chemical machining (ECM) assembly. The ECM assembly includes a machining tool and a flexible line. The machining tool is disposed at the nozzle inlet... forming the nozzle inlet by removing the edge with the machining tool
Data Source
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AI summary
A system for forming a nozzle inlet (80) of a nozzle (70) includes a nozzle body (76) and an electro-chemical machining (ECM) assembly (48). The nozzle body (76) includes an external surface (78). The nozzle body (76) forms a nozzle orifice (72) and a manifold passage (74). The nozzle orifice (72) extends through the nozzle body (76) between and to a nozzle inlet (80) and a nozzle outlet (82). The nozzle inlet (80) is disposed at the manifold passage (74). The nozzle outlet (82) is disposed at the external surface (78). The ECM assembly (48) is installed on the nozzle body (76). The ECM assembly (48) includes a machining tool (96) and a flexible line (92). The machining tool (96) is disposed at the nozzle inlet (80). The flexible line (92) is attached to the machining tool (96). The flexible line (92) extends through the nozzle outlet (82) from the machining tool (96) to an exterior of the nozzle body (76).