Electrolyte Membrane Filtration for Precise Electrochemical Machining
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Solution Overview
Problem
Existing electrochemical machining methods face challenges in achieving high precision and reproducibility, particularly in machining hard materials like those used in axial turbomachines, and require large volumes of electrolyte liquid, which can be environmentally critical and costly to handle.
Innovation Solution
A membrane filter system is used to recirculate and filter the electrolyte liquid through a tangential flow process, reducing the overall volume needed and enhancing filtration efficiency, allowing for higher dry substance content and reduced energy consumption, without the need for additional chemicals or sedimentation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional ultrafiltration is used, then filtration is achieved, but large volumes of electrolyte liquid are required and filtration capacity is limited
Solution Approach 1:
The membrane is rotated during filtration to create dynamic tangential flow conditions. This rotational movement generates centrifugal forces and shear stresses that enhance the filtration process, allowing for higher filtration capacity and reduced electrolyte volume requirements compared to static filtration systems
Solution Approach 2:
The system utilizes hydraulic principles by creating tangential flow of electrolyte liquid across the membrane surface through rotational movement. This hydrodynamic approach enhances permeate flow and filtration efficiency, enabling the system to achieve order of magnitude higher filtration capacity while reducing the quantity of electrolyte liquid needed
2Productivity
If dead-end filtration is used, then filtration is achieved, but frequent back flushing is required and energy consumption increases
Solution Approach 1:
The rotational movement of the membrane creates continuous tangential flow that prevents particle accumulation and membrane fouling. This dynamic filtration approach eliminates the need for periodic back flushing operations, enabling continuous operation and reducing energy consumption associated with reverse flushing cycles
Solution Approach 2:
The tangential flow condition is established from the beginning of filtration, preventing fouling before it occurs. This preliminary preventive action through controlled flow dynamics avoids the need for corrective back flushing operations that would be required in dead-end filtration systems
3Productivity
If conventional filtration systems are used, then filtration is achieved, but large surface area and spatial requirements result
Solution Approach 1:
The rotating membrane system concentrates the filtration action in a compact rotational space. The tangential flow generated by rotation enhances mass transfer and permeate flow density, allowing achieving order of magnitude higher filtration capacity per unit membrane area compared to conventional static systems
Solution Approach 2:
The system transitions from planar static filtration to three-dimensional rotational filtration. By utilizing the rotational dimension, the system creates enhanced flow patterns and shear stresses that dramatically increase filtration capacity per unit area, reducing the overall surface area and spatial requirements
4Manufacturing precision
If additional chemicals and sedimentation steps are added, then filtration efficiency improves, but process complexity and spatial requirements increase
Solution Approach 1:
The invention extracts and eliminates the need for additional chemical agents and separate sedimentation steps from the filtration process. The rotational tangential flow membrane filtration achieves the required filtration precision through purely physical hydrodynamic mechanisms, simplifying the overall process while maintaining machining 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
This approach results in improved precision, reduced environmental impact, and increased efficiency in electrochemical machining by minimizing the volume of potentially hazardous electrolyte liquid, achieving higher permeate flow and filtration capacity, and facilitating more uniform machining conditions.
Implementation Method 1
the electrolyte liquid flows tangentially over the membrane thereof
Implementation Method 2
In comparison to an ultrafiltration (dead-end operation or cross-flow operation)
Implementation Method 3
the relative movement occurs by way of a rotational movement of the membrane
Implementation Method 4
the electrolyte liquid flows tangentially over the membrane
Implementation Method 5
a workpiece by electrochemical removal
Implementation Method 6
an electron current can be adjusted in the work gap during machining and brings about the dissolution of metal cations from the metal workpiece
Data Source
AI summary
The invention relates to a method for machining a workpiece by an electrochemical machining process in which material is removed from the workpiece in an electrolyte liquid, where the electrolyte liquid is then filtered in a membrane filter system which has a membrane that undergoes a relative movement in the membrane filter system during the filtering process, and the filtered electrolyte liquid is reused for the electrochemical machining process.