Resonant Vibration Coupling for Electroerosion Machining
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Solution Overview
Problem
The machining of workpieces, particularly in creating small features like bores in injection valves, is time-consuming using existing non-contact removal processes such as electroerosion and laser ablation, which require precise and efficient material removal methods.
Innovation Solution
A method and device that utilize an excitation oscillation at a self-resonant frequency of the workpiece or a combination of the workpiece and a coupling element to achieve maximum oscillation amplitude in the machining region, synchronizing the oscillation with the non-contact removal process, such as electroerosion or laser ablation, to enhance energy efficiency and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If non-contact removal process (electroerosion or laser ablation) is used to machine small features like bores, then machining precision is improved, but machining time increases significantly
Solution Approach 1:
The workpiece is excited by means of an excitation oscillation having a self-resonant frequency of the workpiece or a combination comprising the workpiece and a coupling element. The self-resonant frequency is selected such that in the machining region an oscillation occurs that has a maximum oscillation amplitude in relation to an excitation amplitude of the excitation oscillation. This mechanical vibration superimposed on the non-contact removal process accelerates material removal while maintaining precision.
Solution Approach 2:
The excitation oscillation is applied periodically at the self-resonant frequency of the workpiece, creating rhythmic vibrations that enhance the material removal rate during electroerosion or laser ablation, thereby reducing overall machining time while preserving machining precision.
2Productivity
If excitation oscillation at self-resonant frequency is applied to reduce machining time, then productivity is improved, but device complexity increases
Solution Approach 1:
A coupling element is introduced as an intermediary between the actuator and the workpiece. The coupling element is coupled rigidly to the workpiece and has a self-resonant frequency that matches the excitation oscillation frequency, enabling efficient vibration transmission while isolating the actuator from direct contact with the workpiece, thus simplifying the overall system design.
3Productivity
If maximum oscillation amplitude is achieved in machining region, then material removal efficiency is improved, but wear on actuator increases
Solution Approach 1:
The coupling element serves as a mediator that transmits vibrations from the actuator to the workpiece. By coupling the actuator to the coupling element rather than directly to the workpiece, the system achieves maximum oscillation amplitude in the machining region while protecting the actuator from excessive wear through the buffering effect of the coupling element.
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 reduces machining time, increases efficiency, and minimizes wear on the actuator and tool, enabling high-quality mass production with reduced cycle times and precise machining of microfeatures.
Implementation Method 1
the workpiece is excited by means of an excitation oscillation having a self-resonant frequency of the workpiece or a combination comprising the workpiece and a coupling element that is coupled rigidly to the workpiece is excited by means of an excitation oscillation having a common self-resonant frequency of the workpiece and the coupling element, wherein the self-resonant frequency is selected such that, in the machining region, an oscillation occurs that has a maximum oscillation amplitude
Implementation Method 2
The tool is brought close to the workpiece without coming into contact therewith. By applying an electrical voltage between the tool and the workpiece, an arc or a spark is produced for a short period of time, by means of which material can be detached from the workpiece and removed
Implementation Method 3
the non-contact removal process is laser ablation with a predetermined pulse frequency
Data Source
AI summary
A method and related device for machining a workpiece is provided, wherein material of the workpiece is removed in a machining region by a non-contact removal process. The workpiece is excited by means of an excitation oscillation having a natural resonant frequency of the workpiece, or a composite comprising the workpiece and a coupling element that is rigidly coupled to the workpiece is excited by means of an excitation oscillation having a joint natural resonant frequency of the workpiece and the coupling element. The natural resonant frequency is selected such that in the machining region an oscillation occurs that has a maximum oscillation amplitude in relation to the excitation amplitude of the excitation oscillation.