Fluid Flushing for Internal Channel Debris Removal in Machined Parts
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Solution Overview
Problem
Additive manufacturing introduces challenges in managing Foreign Object Debris (FOD) due to the creation of intricate internal structures that trap debris, which can obstruct fluid flow and cause efficiency issues or damage, and existing methods to manage FOD in subtractive manufacturing can inadvertently introduce debris into these structures.
Innovation Solution
A fluid flushing system is employed to connect a part with internal channels to a fluid pump, pressurize the part, breach the channels to form openings, and pump fluid through to create a current that flushes away debris, utilizing adapters, manifolds, and rotating fluid distribution devices to maintain fluid communication and orientation independence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to create intricate internal structures, then manufacturing capability and design flexibility are improved, but Foreign Object Debris can trap in these structures causing obstruction and damage
Solution Approach 1:
The system pressurizes fluid through internal channels before machining operations begin, preparing the flushing system in advance. This preliminary pressurization ensures that when openings are created in the channels, the pressurized fluid immediately flows out to flush away debris, preventing FOD from trapping in the intricate structures during the manufacturing process.
Solution Approach 2:
The invention uses a fluid pumping system that pressurizes liquid (such as coolant or flushing fluid) through the internal channels of the additively manufactured part. The pressurized fluid flows through the intricate internal structures and exits through newly created openings, using hydraulic pressure to transport and flush away Foreign Object Debris, thereby solving the debris obstruction problem while maintaining the complex internal geometry.
2Reliability
If fluid flushing is used to remove debris, then FOD removal effectiveness is improved, but system complexity increases due to pumps, adapters, and fluid management components
Solution Approach 1:
The fluid pumping system serves multiple functions: it pressurizes the internal channels before machining, provides cooling during machining operations, and flushes away debris through the created openings. By combining these functions into a single integrated system, the invention reduces overall system complexity while maintaining effective FOD removal capability.
Solution Approach 2:
The system uses the machining operation itself to create the openings needed for fluid egress. As the machining device removes material to create features, it simultaneously creates openings in the internal channels that allow pressurized fluid to flow out and flush debris. This self-service approach eliminates the need for separate flushing openings or complex additional components.
3Ease of manufacture
If existing FOD management methods from subtractive manufacturing are applied, then debris management experience is utilized, but debris may be inadvertently introduced into internal structures
Solution Approach 1:
Instead of trying to prevent debris from entering channels during machining (the conventional approach), the invention inverts the strategy by pressurizing fluid to flow outward through the channels. The pressurized fluid creates a outward-flowing current that actively pushes debris away from the internal structures and out through the machining openings, reversing the typical inward-contamination risk.
Solution Approach 2:
The system maintains continuous pressurization of fluid through the internal channels throughout the machining operation. This continuous pressurized flow ensures that debris is constantly being flushed away rather than allowing intermittent or post-process cleaning, thereby preventing debris introduction while utilizing the continuous nature of modern CNC machining operations.
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 system effectively removes FOD by creating a fluid current that flushes debris away, maintaining fluid flow and cooling the machining device, while reducing the risk of debris obstruction and enhancing manufacturing efficiency.
Implementation Method 1
operating the pump to pressurize the part with a fluid
Implementation Method 2
pumping the fluid through the internal channel and the opening to produce a fluid current
Implementation Method 3
pumping the fluid through the internal channel and the opening provides sufficient cooling for a machining operation of the machining device
Data Source
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AI summary
Methods, apparatus, and devices for fluid flushing systems to remove foreign object debris (FOD) are provided. These methods and devices are designed to flush and transport FOD away from machined parts. Foreign object debris refers to any unintended material such as tiny particles, chips that enters a part during a manufacturing process. FOD can have significant effects, compromising the quality and functionality of manufactured items. This can lead to costly consequences such as rework, scrapped parts, and production delays. FOD prevention is essential for improving safety, reliability, and efficiency.