Pulse Electrochemical Leveling of Revolving Parts With Dynamic Voltage
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Solution Overview
Problem
The existing electrochemical machining methods for casing parts in aeroengines face challenges such as long machining periods, tool wear, high costs, and poor wall thickness uniformity due to the use of hard-to-cut materials and thin-walled structures, leading to deformation and reduced machining accuracy.
Innovation Solution
A pulse dynamic electrochemical machining apparatus and method that uses a power source, displacement sensor, and control system to collect and analyze the outer cylindrical contour data of the anode workpiece, dynamically adjusting the machining voltage to rapidly level the surface by maximizing corrosion at high points and minimizing it at low points, thereby controlling deformation and ensuring consistent inter-electrode gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional numerical control machining is used for casing parts, then machining can be performed on hard-to-cut materials, but the machining period is long, tool wear is serious, and machining cost is high
Solution Approach 1:
The patent replaces traditional mechanical cutting methods with electrochemical machining, which uses electrochemical reactions to remove material. This substitution eliminates mechanical tool wear and reduces machining time for hard-to-cut materials like super alloys and titanium alloys used in casing parts
Solution Approach 2:
The patent introduces pulse dynamic voltage parameters to control the electrochemical dissolution rate. By dynamically adjusting voltage during machining, the process achieves high removal rates while maintaining precision, resolving the contradiction between productivity and manufacturing quality
2Productivity
If traditional milling is used for thin-walled casing parts, then material can be removed, but residual stress is produced causing severe deformation and poor wall thickness uniformity
Solution Approach 1:
The patent replaces mechanical milling forces with electrochemical dissolution, eliminating cutting stresses that cause deformation in thin-walled parts. The electrochemical process removes material without mechanical contact, preserving wall thickness uniformity and avoiding residual stress
Solution Approach 2:
The patent applies localized electrochemical dissolution at the tool-workpiece interface, allowing precise control of material removal in specific areas. This localized action maintains overall part geometry and wall thickness uniformity while achieving necessary material removal
3Manufacturing precision
If counter-rotating electrochemical machining is used, then material is dissolved layer by layer with controlled deformation, but the leveling process of the outer cylindrical contour is slow requiring a long transitional period
Solution Approach 1:
The patent introduces dynamic voltage adjustment during the electrochemical machining process. By making the voltage parameter time-dependent and adaptive to the instantaneous inter-electrode gap, the system accelerates the leveling process while maintaining controlled deformation, resolving the contradiction between precision and productivity
Solution Approach 2:
The patent employs pulse dynamic voltage with periodic on-off cycles during machining. This periodic action enhances material removal efficiency during the leveling phase while maintaining precision, reducing the transitional period needed to achieve equilibrium state
4Ease of operation
If constant voltage is applied during electrochemical machining, then the process is simple to control, but different dissolution rates occur at different points due to varying inter-electrode gap, resulting in slow leveling
Solution Approach 1:
The patent implements a feedback control system that uses displacement sensors to detect inter-electrode gap variations and dynamically adjusts voltage accordingly. This closed-loop control maintains simple operation while significantly improving leveling efficiency by compensating for gap variations in real-time
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 significantly shortens the transition time to a stable machining state, improving the efficiency and precision of the machining process, ensuring consistent wall thickness and enhanced surface quality of casing parts.
Implementation Method 1
Electrochemical machining is a nontraditional machining method for removing materials based on the principle of electrochemical anodic dissolution
Data Source
AI summary
The invention relates to the technical field of electrochemical machining and provides a pulse dynamic electrochemical machining apparatus and method for rapidly leveling a surface of a revolving part. During rotating pulse dynamic electrochemical machining, a cathode tool rotates around a center point of the cathode tool at a constant angular velocity, and an anode workpiece rotates around a center point of the anode workpiece at the constant angular velocity; meanwhile, the cathode tool performs a feed movement at a set feed velocity along a center line of the cathode tool and the anode workpiece. A control system determines a machining voltage value output by a power source when each contour point of the anode workpiece rotates to a machining area to automatically change an applied voltage between the cathode tool and the anode workpiece.