Self-Centering ECM Electrode for Precise Turbine Edge Rounding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for electrochemical machining of turbine components lack precision and effectiveness in achieving defined edge radii, leading to suboptimal accuracy and efficiency.
Innovation Solution
An electrode arrangement featuring a tubular working electrode with controlled electrolyte flow and a self-centering mechanism, utilizing a shaped electrode and locking means for precise positioning and material removal, ensuring consistent electrolyte supply and preventing unwanted processing areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional electrode holders are used, then mechanical connection is achieved, but effectiveness and productivity are reduced
Solution Approach 1:
The patent implements self-service through the self-centering mechanism where the attachment element with centering aid automatically positions the electrode carrier concentrically with the recess in the component. This self-centering action occurs when the electrode carrier is inserted into the recess, eliminating the need for external alignment equipment and ensuring consistent positioning accuracy without requiring additional adjustment steps.
Solution Approach 2:
The patent applies dynamics by providing floating mounting that allows the electrode carrier to deviate laterally by a small amount under the influence of lateral forces during machining. This dynamic capability enables the electrode to adapt to slight variations in component positioning or machining forces, maintaining effective contact and consistent machining quality without rigid constraints that would reduce productivity.
2Manufacturing precision
If electrolyte flow is not controlled, then simple electrode design is maintained, but manufacturing precision and material removal accuracy deteriorate
Solution Approach 1:
The patent applies local quality by providing a shaped electrode with a specific negative shape corresponding to the desired edge geometry. This shaped electrode is positioned at the front end of the tubular electrode carrier, creating a localized region with precise geometric properties that directly determines the edge radius accuracy. The electrolyte outlet opening is also strategically positioned to provide concentrated electrolyte flow exactly where material removal is needed, enhancing the precision of the machining process.
Solution Approach 2:
The patent implements taking out by extracting the electrolyte flow control function from a complex external system and integrating it directly into the electrode carrier structure through the outlet opening. This allows precise electrolyte delivery to be achieved through a simple structural feature rather than complex external flow control mechanisms.
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
Enables precise and efficient electrochemical machining of turbine components with defined edge radii, improving accuracy and reducing material removal errors while maintaining economic viability.
Implementation Method 1
a tubular working electrode is provided through which an electrolyte is conducted to carry out the electrochemical removal
Implementation Method 2
electrochemical removal
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an electrode arrangement for the defined rounding or deburring of edges of electrically conductive components, in particular turbine components, by means of electrochemical removal with at least one working electrode (5) which has a tubular electrode carrier through which an electrolyte supply line (10) is provided, wherein the electrode carrier has a closure (13, 18) at the end face which is arranged such that the electrolyte supply line is closed in the axial direction of the electrode carrier, and wherein at least one outlet opening (19) is arranged in the radial direction.The invention further relates to a self-centering electrode arrangement and a system for the defined rounding or deburring of edges of electrically conductive components, in particular turbine parts, by means of electrochemical ablation with at least one corresponding electrode arrangement, as well as a method using the electrode arrangements and the described system.