CN-117245161-B - Method and system for electrochemical machining

Abstract

Methods and systems for electrochemically machining a workpiece are provided. The method may include applying two or more electrical potentials to a tool electrode comprising an array of two or more individual electrodes to generate two or more electric fields between the tool electrode and a workpiece opposite the tool electrode, wherein each of the two or more electric fields is generated by one of the array of two or more individual electrodes.

Inventors

• ANDREW LEE TRIMMER
• John Malotte Cotterier
• Douglas Karl Hoover
• Buglar Han Eltas

Assignees

• 通用电气公司

Dates

Publication Date

20260508

Application Date

20230616

Priority Date

20220617

Claims (16)

1. 1. A method of electrochemically machining a workpiece, the method comprising: Applying two or more electrical potentials to a tool electrode comprising an array of two or more individual electrodes to generate two or more electrical fields between the tool electrode and a workpiece opposite the tool electrode, wherein each of the two or more electrical fields is generated by one of the array of two or more individual electrodes, wherein at least one spacer is positioned between a first electrode and a second electrode of the array of two or more individual electrodes, further comprising delivering a charged or uncharged electrolyte solution between the tool electrode and the workpiece through at least one electrolyte flushing port within the at least one spacer.
2. 2. The method of claim 1, wherein the at least one spacer has a thickness of 100 microns to 2500 microns.
3. 3. The method of claim 1, wherein the first electrode and the second electrode are electrically connected in parallel with the workpiece.
4. 4. The method of claim 1, wherein the two or more electrical potentials comprise a first electrical potential and a second electrical potential.
5. 5. The method of claim 4, wherein at least one of the first potential and the second potential is a direct current potential in the range of 12 volts to 35 volts.
6. 6. The method of claim 4, wherein at least one of the first potential and the second potential is a pulsed potential.
7. 7. The method of claim 6, wherein the pulsed electrical potential has an average electrical potential of 5 to 32 volts.
8. 8. The method of claim 1, wherein at least one of the workpiece and the array of two or more individual electrodes comprises a metallic material comprising a metallic alloy comprising a titanium-based alloy, a niobium-based alloy, a nickel-based alloy, a zirconium-based alloy, an aluminum-based alloy, a palladium-based alloy, a platinum-based alloy, a titanium-aluminum alloy, or a combination thereof.
9. 9. The method of claim 1, wherein the workpiece is an airfoil on a bladed disk.
10. 10. The method of claim 1 further including electrochemically machining the workpiece to have a minimum dimension of less than 2 μm.
11. 11. The method of claim 1, wherein the electrolyte solution interposed between the tool electrode and the workpiece comprises an aqueous salt electrolyte comprising sodium nitrate, sodium chloride, sodium bromide, or a combination thereof.
12. 12. The method of claim 1, wherein applying two or more electrical potentials to the tool electrode is performed selectively such that the tool electrode travels into the workpiece in a non-linear direction.
13. 13. An electrochemical machining system, comprising: A tool electrode comprising an array of two or more individual electrodes, wherein upon application of two or more electrical potentials to the array of two or more individual electrodes, two or more electrical fields are generated between the tool electrode and a workpiece, and wherein each of the two or more electrical fields is generated by one of the array of two or more individual electrodes, wherein at least one spacer is positioned between a first electrode and a second electrode of the array of two or more individual electrodes, further comprising delivering a charged or uncharged electrolyte solution between the tool electrode and the workpiece through at least one electrolyte rinse port within the at least one spacer.
14. 14. The electrochemical machining system of claim 13, wherein the first electrode and the second electrode are electrically connected in parallel with the workpiece.
15. 15. The electrochemical machining system of claim 13, wherein the two or more electrical potentials comprise a first electrical potential and a second electrical potential.
16. 16. The electrochemical machining system of claim 15, further comprising a controller configured to independently control the first and second electrical potentials.

Description

Method and system for electrochemical machining Technical Field The field of the present disclosure relates generally to electrochemical machining and, more particularly, to methods and systems for performing electrochemical machining. Background Electrochemical machining (ECM) is a process that removes conductive material (e.g., metallic material) by an electrochemical process. It is commonly used for machining (treating/finishing) workpieces composed of electrically conductive materials. ECM is particularly useful for metals and alloys with high hardness, which makes them difficult to process by conventional methods. For example, ECM may be used to process nickel-based alloys to fabricate various workpieces. During the ECM process, an applied potential is used to oxidize the conductive material from the workpiece, allowing current to flow at a controlled rate. The workpiece acts as an anode and is separated from the tool electrode, which acts as a cathode, by a gap. Electrolyte (typically a saline solution) flows through the gap, flushing away the oxidized material on the workpiece. The workpiece is machined to a shape complementary to the tool electrode as the tool electrode is moved toward the workpiece to maintain the controlled gap. Drawings A full and enabling disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: FIG. 1 shows a schematic front view of an exemplary electrochemical machining system including a tool electrode that includes an array of two or more individual electrodes, the array not being in operation; FIG. 2 shows a schematic front view of an exemplary electrochemical machining system including a tool electrode comprising an array of two or more individual electrodes, the array being in operation; FIG. 3 shows a bottom perspective view of the tool electrode of FIGS. 1 and 2; FIG. 4 illustrates a schematic diagram of a computing system including computing devices, wherein one of the computing devices may function the same or similar to the controller of the present disclosure; FIGS. 5A-5D are schematic diagrams illustrating exemplary embodiments of tool electrode travel into a workpiece in a non-linear direction, and Fig. 6 shows a flow chart of a method of electrochemical machining according to the present disclosure. Repeated use of reference characters in the specification and drawings is intended to represent the same or analogous features or elements of the disclosure. Detailed Description Reference will now be made in detail to the preferred embodiments, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation, not limitation, of the invention. Indeed, it will be apparent to those skilled in the art that various modifications and variations can be made without departing from the scope of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a further embodiment. Accordingly, the present disclosure is intended to cover such modifications and variations as fall within the scope of the appended claims and their equivalents. The word "exemplary" is used herein to mean "serving as an example, instance, or illustration. Any embodiment described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, all embodiments described herein are to be considered as exemplary unless specifically indicated otherwise. Unless specifically stated otherwise herein, the terms "coupled," "fixed," "attached," and the like refer to a direct coupling, fixed or attachment, as well as an indirect coupling, fixed or attachment via one or more intermediate components or features. As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another and are not intended to represent the location or importance of the respective components. In the following description and claims, the singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise. As used herein, unless the context clearly dictates otherwise, the term "or" is not meant to be exclusive and refers to the situation where at least one of the indicated components is present and a combination comprising the indicated components may be present. As used herein, "minimum dimension" refers to the degree of precision that an electrochemical machine is capable of producing on a workpiece. In the prior art, tool electrodes positioned near the workpiece are typically capable of reproducing a surface on the workpiece that has a minimum dimension of 2.54 μm or more. During the ECM process, an applied potential is used to oxidize the conductive material from the workpiece, allowing current to flow at a controlled rate. The workpiece acts as