Steerable Electrode Electromachining for Superalloy Impeller Manufacturing

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Solution Overview

Problem

Traditional machining methods for manufacturing components like compressor impellers from superalloys, such as Inconel, are slow and costly due to the difficulty in cutting and machining these hard materials, leading to extended manufacturing times and high costs.

Innovation Solution

The use of steerable electrodes with six degrees of freedom and rotatable tips in electromachining systems, which dynamically change position and orientation, and transmit high electrical currents for aggressive bulk material removal, combined with a massive parallel manufacturing system that deploys multiple electrodes simultaneously for drilling and pocketing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If traditional CNC milling machines with carbide cutting blades are used to machine superalloys, then the service life of cutting blades is preserved, but the manufacturing speed is substantially slowed

Engineering Contradiction:

Improveservice life of carbide cutting bladesVSAvoidmanufacturing speed

Core Design Contradiction:

Duration of action of moving objectVSProductivity

Solution Approach 1:

The patent replaces mechanical cutting blades with an electromachining system that uses electrical discharge to remove material. The electrode generates electrical discharges that erode the superalloy workpiece without mechanical contact, eliminating wear on cutting tools while dramatically increasing material removal rates.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If electromachining is used for bulk material removal, then manufacturing time is reduced, but manufacturing precision for complex geometries is compromised

Engineering Contradiction:

Improvemanufacturing timeVSAvoidprecision for complex geometries

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent employs a dynamic electrode positioning system with six degrees of freedom that allows the electrode to be steered and repositioned in real-time during the electromachining process. This dynamic capability enables the system to maintain high precision while removing bulk material, as the electrode can adapt its position and orientation to follow complex toolpaths and create intricate geometries.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The electrode positioning mechanism integrates multiple functions into a single system: bulk material removal through electromachining, precise positioning through six-degree-of-freedom control, and complex geometry creation through steerable electrode movement. This multi-functional approach eliminates the need for separate machining operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If multiple sequential machining operations are used to create complex component geometries, then manufacturing precision is maintained, but total manufacturing time is extended to weeks

Engineering Contradiction:

Improveprecision for complex geometriesVSAvoidtotal manufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent merges bulk material removal and precision finishing operations into a single electromachining process. The steerable electrode system can perform both roughing and finishing passes without changing tools or setups, creating complex internal passages and geometries in one continuous operation that previously required multiple sequential steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system performs preliminary positioning and orientation of the electrode along the predetermined transit path before material removal begins. The six-degree-of-freedom positioning mechanism pre-establishes the correct trajectory and angles for creating complex geometries, enabling high-speed material removal while maintaining precision from the start of each operation.

Inventive Principle:

Principle #10Preliminary action

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 accelerates the manufacturing process, reducing the time to manufacture complex components like compressor impellers from weeks to just two to three days by enabling precise and efficient material removal through dynamic positioning and high-current electromachining.

Implementation Method 1

an electromachining system including at least one steerable electrode. Each steerable electrode includes an electrode positioning mechanism configured to facilitate six degrees of freedom referenced to a pitch axis, a yaw axis, and a roll axis

Methodology Applied

Scientific EffectElectromachining: Electrical Discharge Machining

Implementation Method 2

The electrode positioning mechanism includes a first end and a rotatable electrode tip coupled to the first end. The electrode positioning mechanism also includes at least one controller configured to dynamically alter one or more of a shape and an orientation of each steerable electrode

Methodology Applied

Scientific EffectSix degrees of freedom positioning:

Data Source

PatentUS10300544B2Machining and manufacturing systems and method of operating the same

Publication Date: 2019.05.28 GENERAL ELECTRIC CO

AI summary

An electromachining system includes at least one steerable electrode. The steerable electrode includes an electrode positioning mechanism configured to facilitate six degrees of freedom referenced to a pitch axis, a yaw axis, and a roll axis. The three axes are substantially perpendicular to each other. The electrode positioning mechanism includes a first end and a rotatable electrode tip coupled to the first end.