pECM Turbine Component Support for Deflection-Controlled Machining
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Solution Overview
Problem
Pulsed electrochemical machining (pECM) processes face accuracy and precision issues due to the force imparted on workpieces, causing deflection during machining, particularly when clamping airfoil coversheets at both ends.
Innovation Solution
A pECM system with a backside support to stabilize the workpiece span between clamps, maintaining precision by minimizing deflection and enhancing material removal through controlled positioning and electrolyte management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clamps are used to hold the workpiece at both ends, then the workpiece is secured during machining, but the workpiece deflects under the imparted force reducing accuracy
Solution Approach 1:
A support structure is introduced as an intermediary element between the workpiece and the machining system. This support acts as a mediator that provides additional stabilization to the workpiece span without interfering with the clamping mechanism or the machining process, thereby reducing deflection and improving machining accuracy
Solution Approach 2:
The solution adds a spatial dimension to the workpiece support system by positioning the support structure underneath the workpiece span. This creates a three-point support system (two clamps plus one support) that distributes the workpiece and reduces deflection in the vertical dimension without affecting the horizontal clamping
2Manufacturing precision
If the tool maintains a tiny interelectrode gap for precision machining, then material removal accuracy is improved, but the workpiece is more susceptible to deflection affecting precision
Solution Approach 1:
The support structure provides beforehand cushioning by preemptively stabilizing the workpiece span before machining forces are applied. This preventive measure reduces the workpiece's susceptibility to deflection during the machining process, maintaining process stability and 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 backside support improves the accuracy and precision of pECM by reducing workpiece deflection, allowing for effective material removal and maintaining the integrity of complex shapes like airfoil components.
Implementation Method 1
Pulsed electrochemical machining (pECM) is a non-contact machining process based on the principles of electrolysis. As the tool moves toward a surface of the workpiece to be machined, a pulsed DC current may be applied to the tool and the workpiece. The workpiece dissolves anodically about the tool
Implementation Method 2
An electrolyte pumped between the tool and the workpiece may remove dissolved metal, heat and hydrogen from the working gap
Data Source
Figure 1A
Figure 1B~1C
Figure 1D
AI summary
A method for pulsed electrochemical machining (pECM) a turbine component, comprising: generating a pulsed direct current between one or more electrodes of a machining tool and the turbine component, wherein the machining tool comprises a tool body defining a tool axis, the tool body comprising the one or more electrodes, each of the one or more electrodes comprising an electrically conductive material and defining a working surface at a distal end of the tool axis configured to face the turbine component; delivering an electrolyte into an interelectrode gap between the working surface of the one or more electrodes and a target surface of the turbine component; and positioning the working surface of the one or more electrodes relative to the target surface of the turbine component to remove material from the target surface of the turbine component.