Electrode Phase Correction for Accurate Curved Hole ECM

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Solution Overview

Problem

Existing electrochemical machining tools face challenges in maintaining accurate phase alignment of electrodes during long machining processes, leading to significant phase shifting and increased machining errors, especially when forming curved holes in materials like turbine blades.

Innovation Solution

A machining position correcting device that includes a position detector to accurately detect the rotational position of feature points on the electrode bar, allowing for zero-point correction and precise control of the electrode phase, thereby reducing phase shifting and machining errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If an electrode with length of 1,000 mm or more is used to machine materials of 800 mm or more, then the machining capability is improved, but phase shifting occurs between the base end and distal end of the electrode, causing machining errors

Engineering Contradiction:

Improveelectrode lengthVSAvoidphase alignment accuracy

Core Design Contradiction:

Length of moving objectVSManufacturing precision

Solution Approach 1:

The phase angle is measured and recorded before the actual machining operation begins. This preliminary measurement allows the system to compensate for phase shifts during machining by referencing the initial aligned position, thereby maintaining machining precision despite electrode flexibility and length.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors the phase angle between the base end and distal end of the electrode during machining operations. This feedback mechanism allows real-time detection and correction of phase shifts, ensuring that machining accuracy is maintained throughout the process even when using long, flexible electrodes.

Inventive Principle:

Principle #23Feedback

2Adaptability or versatility

If the electrode is made flexible to enable curved hole machining, then the adaptability is improved, but the phase angle becomes difficult to fix accurately during attachment

Engineering Contradiction:

Improvecurved hole machining capabilityVSAvoidphase angle measurement accuracy

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The phase angle measurement is performed as a preliminary step before machining begins. By establishing the phase relationship in advance when the electrode is in a known position, the system can account for flexibility-induced variations during subsequent curved machining operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system replaces mechanical phase fixation methods with an electronic measurement and control system. Sensors and control electronics measure the phase angle electrically and magnetically, eliminating the need for purely mechanical alignment methods that are insufficient for flexible electrodes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If no phase correction mechanism is used, then the device complexity is reduced, but machining errors increase significantly during long machining processes

Engineering Contradiction:

Improvephase control system complexityVSAvoidmachining accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

A phase angle measurement system provides continuous feedback during machining operations. This feedback enables the control system to detect and correct phase deviations, maintaining machining accuracy without requiring overly complex mechanical correction mechanisms.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system introduces a measurement intermediary (phase angle sensor) that mediates between the flexible electrode and the control system. This intermediary provides the information needed to compensate for phase shifts without requiring direct complex mechanical coupling or correction mechanisms.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution significantly reduces machining errors and improves accuracy and yield by ensuring precise alignment and phase control during long curved hole machining, enhancing the overall machining process.

Implementation Method 1

an electrochemical machining device that makes an electrolyte flow out of a distal end part of an electrode bar extending along an axis while rotating the electrode bar about the axis to electrochemically machine a material to be machined

Methodology Applied

Scientific EffectElectrochemical machining: Electrolysis

Data Source

PatentUS11135667B2Machining position correcting device and electrochemical machining device

Publication Date: 2021.10.05 MITSUBISHI HEAVY IND LTD

AI summary

A machining position correcting device is configured to be applied to an electrochemical machining device configured to make an electrolyte flow out of a distal end part of an electrode bar extending along an axis while rotating the electrode bar about the axis to electrochemically machine a material to be machined in a range from the distal end part of the electrode bar. The machining position correcting device includes a position detector configured to detect a rotational position of a feature point of the electrode bar.