Electrode Tip Drilling Tool for Variable Geometry Cooling Channels
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Solution Overview
Problem
Existing electrochemical machining techniques, such as shaped-tube electrochemical machining (STEM), are limited in forming cooling channels with variable geometry within turbine blades due to the fixed orientation of electrode tips and rigidity of drilling tools, restricting the geometric complexity of cooling channels.
Innovation Solution
A drilling tool with a forward electrode tip having an outer and inner radial portion, a dielectric sheath, and side electrodes that are selectively operable to form a bore hole with variable geometry by removing material from a conductive work piece using an electrochemical machining system, allowing for non-linear advancement and dimensional changes in multiple planes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed orientation electrode tip and rigid drilling tube are used in STEM, then straight cooling channels with high aspect ratios can be formed, but the geometry of cooling channels is limited and cannot achieve variable geometry
Solution Approach 1:
The patent applies the dynamics principle by making the electrode tip movable relative to the drilling tube, allowing it to change orientation dynamically during the machining process. This enables the formation of cooling channels with variable geometry, including curved and non-linear paths, while maintaining the precision benefits of STEM for high aspect ratio channels.
Solution Approach 2:
The patent segments the drilling tool into distinct components: a rigid drilling tube and a movable electrode tip. This segmentation allows the electrode tip to be independently positioned and oriented, providing geometric flexibility while the rigid tube maintains structural stability and precision for forming high aspect ratio cooling channels.
2Productivity
If the electrode tip is positioned at the leading edge of the drilling tube with fixed orientation, then material can be removed efficiently, but the tool cannot advance non-linearly or modify orientation autonomously
Solution Approach 1:
The electrode tip is designed to move dynamically within the drilling tube, allowing it to advance non-linearly and modify its orientation autonomously during machining. This maintains material removal efficiency while significantly improving tool flexibility for complex cooling channel geometries.
Solution Approach 2:
The patent introduces an intermediary mechanism (the movable electrode tip within the drilling tube) that mediates between the rigid structure needed for efficient material removal and the flexibility needed for complex geometries. The electrode tip acts as a mediator that can change position and orientation while the rigid tube provides structural support.
3Stability of the object's composition
If a rigid elongated drilling tube is used, then structural stability is maintained, but the tool cannot adapt to variable geometry requirements
Solution Approach 1:
The tool is segmented into a rigid drilling tube for structural stability and a movable electrode tip for geometric adaptability. This segmentation allows each component to fulfill its specific function: the rigid tube maintains structural integrity while the movable tip adapts to variable geometry requirements.
Solution Approach 2:
While the drilling tube remains rigid for structural stability, the electrode tip within it is designed to be dynamic, capable of moving and changing orientation. This dynamic element provides geometric adaptability without compromising the overall structural stability of the rigid tube.
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
Enables the formation of continuous, variable-geometry bore holes within conductive work pieces, enhancing the geometric flexibility and efficiency of cooling channel formation, particularly in high-temperature applications like gas turbines, by allowing the drilling tool to advance in multiple dimensions and modify its orientation autonomously.
Implementation Method 1
material is oxidized and removed from the conductive work piece near the leading edge of the drilling tube
Implementation Method 2
STEM is a non-contact electrochemical machining process that utilizes a conductive work piece (i.e., the turbine blades) as an anode, and an elongated drilling tube as a cathode
Data Source
AI summary
A drilling tool for use in machining a conductive work piece is provided. The tool includes a forward electrode tip that includes an outer radial portion and an inner radial portion that extends from a forward face of the outer radial portion. The tool also includes a dielectric sheath that extends circumferentially about the outer radial portion, and at least one side electrode coupled to the dielectric sheath. When electric current is supplied to the forward electrode tip and the at least one side electrode, material adjacent to the forward electrode tip and the at least one side electrode is removed from the conductive work piece. The forward electrode tip and the at least one side electrode are selectively operable to form a bore hole having a variable geometry that extends through the conductive work piece when the material is removed therefrom.