Abstract:
An electrode applied in electro-machining processes, where the electrode includes a main body portion and at least one built-in internal flushing passage for introducing a flushing liquid to a volume between the electrode and a workpiece to be machined. The electrode is made by an additive fabrication process that enables specialized flushing for enhancing waste material evacuation and incorporate special material properties like zones of high electrical conductivity and thermal resistance. The fabrication process produces materials and geometries that could not otherwise be made using conventional processing.
Abstract:
A drilling tool for use in machining a conductive work piece is provided. The tool includes a body portion, a forward electrode coupled to the body portion, and at least one side electrode coupled to the body portion. When electric current is supplied to the forward electrode and the at least one side electrode, material adjacent to the forward electrode and the at least one side electrode is removed from the conductive work piece. Further, the forward electrode and the at least one side electrode are selectively operable to form a bore hole having a variable geometry that extends through the conductive work piece when the material is removed therefrom.
Abstract:
An electroerosion machining system for trepanning and drilling operations is disclosed. The electroerosion machining system includes an electrode assembly configured to machine a desired configuration in a workpiece, a power supply configured to energize the electrode assembly and the workpiece to opposite electrical polarities, an electrolyte supply configured to pass an electrolyte between the electrode assembly and the workpiece, a working apparatus configured to move the electrode assembly relative to the workpiece, and a control system to control the power supply and the working apparatus. The electrode assembly further includes an electrode body in the form of a tube-shaped body, the tube-shaped body defining a hollow interior and one or more replaceable inserts affixed to the electrode body at a working end thereof positioned adjacent the workpiece, the one or more replaceable inserts constructed so as to be selectively attachable and detachable from the working end of the electrode body.
Abstract:
A method of machining a work-piece formed of titanium-based material, using a machining apparatus, is described. The method includes the steps of providing an electrically-conductive electrode contained within a spindle assembly, in a pre-selected distance and position relative to the titanium-based work-piece; while electrically powering the electrode and the work-piece with a power supply. In the process, fluid electrolyte is circulated through at least two pathways in the machining apparatus—an internal conduit within the spindle assembly; and an external conduit. The charged electrode is moved relative to the work-piece in a plunging motion, to remove material from the work-piece at a relatively high rate, using a high-speed electro-erosion (HSEE) process.
Abstract:
A computer-implemented method for forming a three-dimensional workpiece from a block of material using a fluid jet cutting device is implemented by a fabrication system. The method includes receiving an indication of the geometry of the workpiece and generating a three-dimensional tool path to control a cutting head to form the workpiece. Generating the tool path includes receiving an indication of a desired cutting surface on the workpiece, determining a length of the cutting surface, and designating a plurality of waypoints along an edge of the cutting surface. Generating the tool path also includes determining at least one geometric parameter of the cutting surface at each waypoint of the plurality of waypoints, and calculating a speed of the cutting head at each waypoint of the plurality of waypoints based on the determined geometric parameter such that the speed of the cutting head varies along the cutting surface length.
Abstract:
An electrical machining method comprises machining a workpiece by an electrical machining device comprising an electrode; increasing a feedrate of the electrode at a first acceleration if a discharge current passing through the electrode and the workpiece is lower than a discharge current reference; and decreasing the feedrate of the electrode at a second acceleration if the discharge current is higher than the discharge current reference, wherein the second acceleration has an absolute value higher than that of the first acceleration.
Abstract:
A multi-loop controller component for an electric discharge machining (EDM) system includes a plurality of power loop circuits coupled to an output of a power supply of the EDM system and configured to receive DC electric power from the power supply. Each power loop circuitis electrically-isolated from other power loop circuits. The multi-loop controller component also includes a plurality of transistors. Each transistor is coupled to a respective power loop circuit and is configured to switch between an ON state and an OFF state to generate a pulse of the DC electric power through the respective power loop circuit. In addition, the multi-loop controller component has a drive controller coupled to the plurality of transistors. The drive controller is configured to transmit at least one control signal to at least one of the transistors to facilitate switching the transistor between the ON state and the OFF state.
Abstract:
Electrode for an electro-erosion process, includes a shaft, a body coupled to the shaft, a plurality of machining-inserts, an insulated layer, and a flushing cover disposed on the body and coupled to the shaft. The shaft includes a channel, a plurality of first openings and second openings, where each opening is connected to the channel. The body includes a plurality of main-flushing channels, where each channel is connected to a corresponding first opening. The plurality of machining-inserts is spaced apart from each other along a circumferential direction and detachably coupled to a peripheral end portion of the body. Each machining-insert includes at least one third opening connected to a corresponding main-flushing channel. The insulated layer is disposed on top and bottom surfaces of the body. The flushing cover includes a plurality of side-flushing channels and a plurality of fourth openings, where each channel is connected to a corresponding second opening.
Abstract:
A rotor assembly is provided. The rotor assembly includes a rotor shaft and at least one blisk integrally formed with the rotor shaft. The at least one blisk includes an inner rim extending circumferentially about the rotor shaft, and a plurality of blades extending radially outward from the inner rim, wherein the rotor shaft and the at least one blisk are defined from a single billet of material.
Abstract:
An electrode applied in electro-machining processes, where the electrode includes a main body portion and at least one built-in internal flushing passage for introducing a flushing liquid to a volume between the electrode and a workpiece to be machined. The electrode is made by an additive fabrication process that enables specialized flushing for enhancing waste material evacuation and incorporate special material properties like zones of high electrical conductivity and thermal resistance. The fabrication process produces materials and geometries that could not otherwise be made using conventional processing.