EDM MILLING ELECTRODE

Abstract

An apparatus for an electrical discharge machine for milling a shaped cavity in a workpiece includes a hollow electrode having a metallic inner shell with at least one passage for receiving dielectric fluid. A layer including at least one brass alloy is provided over the inner sheel and exhibits a zinc content greater than a zinc content of the inner shell.

Claims

1. An apparatus for an electrical discharge machine for milling a shaped cavity in a workpiece comprising: a hollow electrode having a metallic inner shell including at least one passage for receiving dielectric fluid; and a layer having at least one brass alloy provided over the inner shell and exhibiting a zinc content greater than a zinc content of the inner shell.

2. The apparatus of claim 1, wherein the inner shell comprises one of copper and a copper alloy.

3. The apparatus of claim 1, wherein the brass alloy layer comprises -phase brass.

4. The apparatus of claim 1, wherein the brass alloy layer comprises -phase brass.

5. The apparatus of claim 1, wherein the brass alloy layer comprises a duplex /-phase brass alloy.

6. The apparatus of claim 1, wherein the brass alloy layer has a thickness of about 10-40 m.

7. The apparatus of claim 1 further comprising a nonmetallic layer including zinc oxide extending over the brass alloy layer and defining the outer surface of the electrode.

8. A method of forming an electrode for an electrical discharge machine for drilling a hole in a workpiece comprising: providing a metallic inner shell having at least one passage for receiving dielectric fluid; depositing a layer of zinc over the inner shell to form a composite electrode; heat treating the composite electrode in an oxygen environment to form a layer having at least one brass alloy over the inner shell; and drawing the composite electrode down to a finish diameter.

9. The method of claim 8, wherein the metallic inner shell comprises one of copper and a copper alloy.

10. The method of claim 8, wherein the brass alloy layer comprises -phase brass alloy.

11. The method of claim 8, wherein the brass alloy layer comprises -phase brass alloy.

12. The method of claim 8, wherein the brass alloy layer comprises a duplex /-phase brass alloy.

13. The method of claim 8, wherein the brass alloy layer has a thickness of about 10-40 m.

14. The method of claim 8, wherein the step of heat treating comprises: heating the composite electrode a first time in an oxygen atmosphere at a first temperature; and heating the composite electrode a second time in an oxygen atmosphere at a second temperature greater than the first temperature.

15. The method of claim 8, wherein heat treating the composite electrode forms an intermediate layer of -phase brass between the core and a -phase brass layer.

16. The method of claim 15, wherein drawing the composite fire forms discontinuities in the -phase brass layer and extrudes the -phase brass wire into the discontinuities.

17. The method of claim 8, wherein the -phase brass layer is continuous.

18. The method of claim 8, wherein drawing the composite wire forms discontinuities in the -phase brass layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a schematic illustration of an example apparatus for performing EDM milling.

[0014] FIG. 2 is an enlarged view of a portion of FIG. 1.

[0015] FIG. 3 is a front view of an EDM milling electrode for the apparatus of FIG. 1.

[0016] FIGS. 4A-4C are alternative configurations for the longitudinal cross-section of the electrode of FIG. 3.

[0017] FIG. 5A is a schematic illustration of a prior art EDM wire construction.

[0018] FIG. 5B is a schematic illustration of the EDM milling electrode of FIG. 3 having a coating in accordance with the present invention.

[0019] FIG. 6 is a metallographic image of a cross-section of a first sample tube electrode of the present invention.

[0020] FIGS. 7A-7C are metallographic images of cross-sections of the first sample tube electrode at different locations around its circumference.

[0021] FIG. 8 is a metallographic image of a cross-section of a second sample tube electrode of the presented invention.

[0022] FIG. 9 is a metallographic image of a cross-section of a third sample tube electrode of the present invention.

[0023] FIG. 10 is a metallographic image of a cross-section of a fourth sample tube electrode of the present invention.

[0024] FIG. 11 is a metallographic image of a cross-section of the fourth sample tube electrode at a different stage of manufacturing than FIG. 10.

DETAILED DESCRIPTION

[0025] The present invention relates generally to EDM milling and, more specifically, relates to an EDM milling electrode coated with high zinc content brass alloys. FIG. 1 shows an apparatus 10 for performing EDM milling, e.g., fast-hole drilling, on a workpiece 24. The apparatus 10 includes a spindle 12 and an electrode guide 14 that cooperate to receive an EDM electrode 40. The electrode 40 is rotatable by the spindle 12 in the direction generally indicated by the arrow R. Alternatively, the spindle 12 could be held stationary (not shown). The electrode 40 is also movable in a longitudinal direction D (vertical as shown) by the apparatus 10 towards the workpiece 24 during operation of the apparatus 10 and as the electrode 40 wears, i.e., shortens.

[0026] Referring to FIGS. 1-3, the electrode 40 is hollow and elongated, extending from a first end 42 to a second end 44. The first end 42 terminates at an axial end face 48. The second end 44 terminates at an axial end face 50. A passage 52 extends through the electrode 40 from the end face 48 to the end face 50. Alternatively, as shown in FIGS. 4A-4C, the electrode 40 can include two passages 52 (FIG. 4A), three passages (FIG. 4B) or four passages (FIG. 4C). In any case, each passage 52 can have a round or polygonal cross-section.

[0027] As shown in FIG. 1, the first end 42 of the electrode 40 extends into and is held by the spindle 12. The electrode 40 also extends through the guide 14 such that the second end 44 extends below the guide. A source of dielectric fluid 22, e.g., deionized water, is fluidly connected to an inlet 20 on the apparatus 10.

[0028] In operation, the workpiece 24 is positioned beneath the electrode 40 in a desired orientation. The electrode 40 is rotated in the direction R and high pressure, dielectric fluid 22 is supplied to the passages 52 via the inlet 20. A power source 60 electrically connected to the electrode 40 applies a pulsed electric potential thereto. When the end 44 of the electrode 40 is in close proximity with the workpiece 24, the intensity of the electric field generated in the electrode is sufficient to form an electrical discharge in a gap G between the end 44 and the workpiece. In other words, current flows between the end 44 of the electrode 40 and the workpiece 24. As a result, particles 32 are removed from the workpiece 24 and the electrode 40 to form recesses 34 therein. The dielectric fluid 22 helps flush the removed particles 32 from the workpiece 24 in the manner generally indicated by the arrow A. Continued removal of the particles 32 eventually forms a shaped cavity and/or hole 26 in the workpiece 24. This hole 26 can extend entirely through the workpiece 24 (indicated in phantom in FIG. 3). With that said, the present invention introduces a coating for the electrode 40 that significantly improves hole drilling performance over existing electrodes for fast-hole drilling EDM machines.

[0029] An example of an existing, high performance diffusion annealed, coated EDM wire 100 is shown in FIG. 5A. The wire 100 extends along a longitudinal centerline 102 and includes a core 104 formed at least in part from copper. At least one high zinc content brass alloy layer 106 is provided on the core 104. The thickness of the brass alloy layer 106 is about 4 m-15 m, depending on its phase type(s).

[0030] The brass alloy layer 106 is formed by diffusion annealing, which typically is performed in air. As a result, a zinc oxide layer 108 is formed on the surface of the brass alloy layer 106. Prior art EDM wire constructions limited the thickness of the zinc oxide layer 108 to about 1 m since its effectiveness as a semi-conductor barrier decreases with thickness at the low currents typically employed.

[0031] The present invention improves this coating concept for adaptation to the high current milling application by increasing the thickness of a brass alloy 76 layer on the electrode 40 compared to the wire 100 to create a significant area percentage of the total exposed area of the end face 50 projected on the discharge location across the gap G in the workpiece 24. Optionally, a heavier zinc oxide layer can be provided on the electrode 40 to limit current leakage along the gap G between the side of the end 44 of the tubular electrode 40 and the wall of the hole 26 being milled. The oxide layer, however, can be omitted.

[0032] To this end, FIG. 5B illustrates an axial cross-section of the coated electrode 40 in accordance with the present invention. The electrode 40 extends along a longitudinal centerline 72 and includes a core inner shell 74. The core inner shell 74 is formed at least in part from, for example, copper, or a copper zinc alloy. At least one high zinc content brass alloy phase layer 76 is provided on the core inner shell 74. The brass alloy layer 76 could be a single phase layer, e.g., -phase brass or -phase brass, or sequential single phase layers one on top of another, e.g., discontinuous -phase brass over -phase brass. Alternatively, the brass alloy layer 76 can include a two phase mixture, e.g., -phase precipitates in a -phase matrix, -phase precipitates in a -phase matrix, or any combination of layers thereof. In any case, the thickness of the brass alloy layer 76 is typically 10-40 m.

[0033] The brass alloy layer 76 is formed by diffusion annealing, which typically is performed in air or an oxygen enriched environment. More specifically, a zinc layer is provided on the core inner shell 74 by, for example, electroplating, to form a composite electrode. The composite electrode is then diffusion annealed to transform the zinc layer into the brass alloy layer or layers 76. The first heat treatment can be at a temperature of about 150 C.-160 C. A second heat treatment can be about 275 C.-500 C. Either heat treatment can last from about 7-16 hours. The composite electrode 40 is subsequently drawn to a finish diameter and cut to length, typically 300-400 mm. The zinc oxide layer 78 can be removed from the electrode 40 prior to or following drawing.

[0034] The specific construction of the brass alloy layer 76 depends on the annealing temperature, time, and number of different heat treatments performed on the tube electrode 40. Since the diffusion annealing is performed in an oxygen containing atmosphere, the outer portion of the zinc layer exposed to air is oxidized to form an outer zinc oxide layer 78 extending at least partially over the surface of the brass alloy layer 76 after drawing and finish processing to straighten and size the electrode 40.

[0035] The diffusion annealing process described herein allows one to advantageously thicken the oxide layer 78 to convert it from a semi-conductor to more of an insulating layer by adjusting the heat treating process parameters of time, temperature, and/or atmosphere. As a result, the thickness of the zinc oxide layer 78 can be as thick as 15 m and as thin as 0 m, depending on where along the circumference of the electrode 40 the measurement is taken. Such an adapted structure in the electrode 40 would be able to provide for limiting any side wall current leakage and to identify the potential of an increased exposed alloy layer 76 area projected on the discharge location thereby disproving the prevailing thought that such surface coatings are inherently ineffective. The following are examples detailing processes and constructions of tube electrodes in accordance with the present invention.

EXAMPLE 1

[0036] A tube electrode construction identified as the GBT150 sample 140 was created using the process schedule itemized below: [0037] 1. Electroplate 6 m of zinc on a 1.2 mm outer diameter/0.40 inner diameter, single channel tube preform of alloy 65Cu/35Zn. [0038] 2. Heat treat at 150 C. for 16 hours in air. [0039] 3. Draw in three passes (1.140-1.034-0.098 mm) to finish diameter. [0040] 4. Finish process (straighten, size, and cut to length).

[0041] FIG. 6 is a metallographic image of the resultant tube electrode 140 cross-section taken at the conclusion of Step 2. Analysis of the microstructure in FIG. 6 and other random cross-sections of the tube electrode 140 indicates the GBT150 samples prior to drawing had a -phase brass alloy layer 76 approximately 18-20 m thick and an oxide layer 78 which was at least 4+m thick.

[0042] FIGS. 7A-7C illustrate different area about the circumference of a single cross-section of a finished tube electrode 140 of the GBT150 sample where the -phase brass layer 76 has radially fractured and the oxide layer 78 is not uniform around the tube circumference. In some areas, the oxide layer 78 is thicker where it has agglomerated (FIG. 7A). In other areas, the oxide layer 78 is reasonably unchanged where there was better bonding with the underlying brass layer 76 and, thus, the oxide layer was undisturbed by the drawing process. In still some other areas, the oxide layer 78 appears to have been stripped off the tube electrode 140 so as to be essentially removed (FIG. 7C).

[0043] The fracturing of the -phase brass alloy layer 76 was expected as it is well known in the prior art wire EDM technology that the extreme brittleness of the -phase brass alloy results in it not being able to tolerate deformation processing, such as wire or potentially tube drawing (see Tomalin (U.S. Pat. No. 5,945,010). As a result, the coating layer thicknesses of -phase brass alloy coated wire is typically limited to less than 6 m since the wire application usually requires the wire electrodes to be hard drawn to tensile strengths of 750-900 N/mm.sup.2 to facilitate auto-threading wire accessories. On the other hand, tube drawing is more of an elongation rather than a deformation process and, thus, thicker -phase brass coatings can be utilized on the milling tubes such as those in the present invention.

EXAMPLE 2

[0044] To further illustrate the versatility available in diffusion anneal coated tube electrodes, some of the GBT150 samples 140 prepared in Example 1 were heat treated a second time to form GBT400 tube electrode samples 340 shown in FIG. 9. The second heat treatment was performed at 400 C. for 7 hours in a dynamic (flowing) air atmosphere. The higher temperature heat treatment converted the brass alloy layer 76 from -phase brass to -phase brass, which has several significant consequences.

[0045] Although the zinc content of -phase brass is lower than that of -phase brass (45% zinc versus 65% zinc), the diffusion anneal drives the zinc radially inward from the brass alloy layer 76deeper into the core inner shell 74. This thickens the brass alloy layer 76, as illustrated in FIG. 9, from 18-20 m to 26-28 m. This thicker coating increases the coating area percentage of the exposed face on the end 44 of the tube electrode tube 340 of the GBT400 coating to 23.7%, compared to an 8.9% value for the GBT150 samples 140. Further, the -phase brass coating 76 of the GBT400 sample 340 is considerably more ductile than that of the -phase brass coating of the GBT150 sample 140. This would provide significantly more latitude in processing the coated tubes to finish size without fracturing the coating were it to be drawn directly to finish size after heat treatment. For the purpose of illustration here, the conversion to a -phase brass alloy layer 76 was performed at the finish size of the electrode 340 processing sequence but it also could be performed after the zinc deposition process (Step 1), and would be capable of being drawn to the same finish diameter because of its adequate ductility even though it is often reported to be a brittle phase.

EXAMPLE 3

[0046] A large number of the applications for fast hole drilling EDM require a hole diameter ranging in size from 0.5 mm to 1.0 mm. Therefore, a tube electrode construction identified as the GBT150-0.5 sample 440 was created using the process schedule itemized below: [0047] 1. Electroplate 6 m of zinc on a 1.2 mm outer diameter/0.92 inner diameter, single channel tube preform of alloy 65Cu/35Zn. [0048] 2. Heat treat at 150 C. for 16 hours in air. [0049] 3. Draw in six passes (1.083-0.99-0.892-0.75-0.593-0.493 mm) to finish diameter. [0050] 4. Finish process (straighten, size, and cut to length).

[0051] FIG. 10 is a metallographic image of the resultant tube electrode 440 cross-section taken at the conclusion of Step 2. Analysis of the microstructure in FIG. 10 and other random cross-sections of the tube electrode 440 indicates the GBT150-0.5 samples prior to drawing had a -phase brass alloy layer 76 approximately 12-18 m thick and an oxide layer 78 which is 2-4 m thick. FIG. 11 illustrates the cross-section of a finished tube electrode 440 of the GBT150-0.5 sample where the -phase brass layer 76 has been fractured during drawing. The oxide layer 78 has been agglomerated and is uniformly, but discontinuously, distributed around the circumference of the tube electrode 440.

Results

Comparison to State of the Art Tube Electrode Performance

[0052] The two applications of the fast hole drilling technology that are important to high temperature turbine design are through hole drilling of cooling passages and shaped hole drilling of diffuser pockets (see ForresterU.S. Pat. No. 7,041,933). Performance test comparisons were made between tube electrodes of the current invention and state of the art tube electrodes on state of the art equipment in use for both applications. The state of the art electrodes used for comparison were single channel, uncoated brass (65Cu/35Zn) tubes 300 mm in length which were sourced from Global EDM Supplies, Part No. BR-1x300T for 1.0 mm diameter and BR-0.5x300T for 0.5 mm diameter.

[0053] To evaluate the GBT150 sample 140 of the current invention, through hole performance tests were performed on an Ocean FH350 CNC 32 amp model machine tool. Three holes were machined in a 1.0 inch thick block of D-2 tool steel hardened to R.sub.c 52-54. Both electrode types were operated on the manufacturer's recommended technology for the test conditions which is designated SKD 1.0 mm tech and both electrode types were operated under that standard technology to a full depth of 1.0 inch with a flushing pressure of 800 PSI. The parameters for the SKD 1.0 mm tech were:

TABLE-US-00001 On time Off time IP VS C Box Gap Rot-S Feed Pulse 30 20 15 3 0 24 15 30 0

[0054] The results of this series of test are summarized below:

Brass Electrode:

[0055]

TABLE-US-00002 Time Total time Hole Amps Break thru to break thru (break thru-finish) Hole 1 9-10 1.70 00:01:03 00:02:49 0.040 2 9-10 1.82 00:01:04 00:02:03 0.042 3 9-10 1.87 00:01:06 00:01:43 0.041

GBT150 (Gamma Phase Brass Coated) Electrode:

[0056]

TABLE-US-00003 Time Total time Hole Amps Break thru to break thru (break thru-finish) Hole 1 11-12 1.70 00:00:54 00:01:40 0.042 2 11-12 1.72 00:00:58 00:01:40 0.042 3 11-12 1.87 00:01:00 00:01:40 0.042

GBT400 (Beta Phase Brass Coated) Electrode:

[0057]

TABLE-US-00004 Time Total time Hole Amps Break thru to break thru (break thru-finish) Hole 1 11-12 1.78 00:00:58 00:01:31 0.043 2 11-12 1.80 00:00:56 00:01:28 0.043 3 11-12 1.87 00:00:57 00:01:29 0.043

[0058] To evaluate the GBT150-0.5 sample of the current invention, through hole performance tests were also performed on an Ocean FH350 CNC 32 amp model machine tool. Three consecutive holes were machined in a 0.285 inch thick block of D-2 tool steel hardened to R.sub.c 52-54. Both electrode types were operated on the manufacturer's recommended technology for the test conditions which is designated SKD 0.5 mm tech and both electrode types were operated under that standard technology to a full depth of 1.0 inch with a flushing pressure of 1000 PSI. The parameters for the SKD 0.5 mm tech were:

TABLE-US-00005 On time Off time IP VS CBox Gap Rot-S Feed Pulse 25 20 10 2 0 22 15 30 0

[0059] The results of these tests were:

Brass Electrode:

[0060]

TABLE-US-00006 Time Total time Hole Amps Break thru to break thru (break thru-finish) Hole 1 7-8 0.46 00:00:18 00:00:38 0.022 2 7-8 0.52 00:00:28 00:00:49 0.022 3 7-8 0.59 00:01:06 00:02:15 0.022

GBT150-0.5 Electrode:

[0061]

TABLE-US-00007 Time Total time Hole Amps Break thru to break thru (break thru-finish) Hole 1 8-9 0.45 00:00:14 00:00:32 0.022 2 8-9 0.46 00:00:16 00:00:34 0.022 3 8-9 0.47 00:00:18 00:00:36 0.022

[0062] The EDM machine tool used to evaluate the performance observed in shaping a simulated diffuser pocket profile with each electrode type was a Beaumont Model BM 8060-63A. The workpiece was a sheet of Inconel 0.125 inch thick positioned at angle of 60 to simulate a blade component for a turbine. The results of this series of tests together with the adjustments made to the machine technology for both electrode types which minimized short circuit interruptions are summarized below:

TABLE-US-00008 On time Off time IP C Box Feed 30 20 18 0 3.0

[0063] Three shaped pockets were formed in each workpiece from each electrode. The same settings and conditions were used for each cut, to a full depth of 1.0 inch with a flushing pressure of 800 PSI.

Brass Electrode:

[0064]

TABLE-US-00009 Shape Total time 1 00:02:30 2 00:02:37 3 00:02:41

GBT150 (Gamma Phase Brass Coated) Electrode:

[0065]

TABLE-US-00010 Shape Total time 1 00:01:41 2 00:01:36 3 00:01:38

GBT400 (Beta Phase Brass Coated) Electrode:

[0066]

TABLE-US-00011 Shape Total time 1 00:02:27 2 00:01:48 3 00:01:52

Through-Hole Performance Analysis

[0067] Using Ocean's suggested machine technology for 1.0 mm diameter tube electrodes, all of the coated tube electrodes of the present invention equaled or outperformed the state of the art brass tube electrodes. The coated electrodes of the present invention marginally reduced the cycle time to break-through by an approximate 2-5% compared to the brass electrode. However, total cycle time per hole with the coated electrodes of the present invention was reduced by about 25-30% compared to the state of the art brass electrodes.

[0068] Some of the advantage of the coated tube types was probably due to the marginally higher current the coated types drew, but the largest contribution to the reduction in total cycle time was due to the coatings' ability to dress the burr on the exit edge after the internal flush was lost at break-through. The coated electrodes exhibited noticeably less shorting which required the electrode to be temporarily withdrawn to clear the short circuit throughout the cycle, but after break-through the reduction in shorting was dramatic. In the case of the prior art 0.5 mm brass electrodes, it is clear from the test results that the electrode end deteriorated with each pass, causing the time for break-through and the total time for each pass to consecutively increase with increasing increments. By way of contrast the coating on the GBT500-0.5 sample of the present invention maintained the end integrity of the electrode, thereby providing consistent performance with each pass. Although the initial cutting speeds of the brass and coated electrodes were approximately equal at the smaller 0.5 mm diameter, the coated electrode could maintain that performance with consecutive operations whereas the bare brass electrode could not. This is desirable in industrial applications where multiple hole drilling operations are very common.

Diffuser Pocket Performance Analysis

[0069] The cycle time for milling the simulated pocket cavity was decreased by more than 50% for both coated electrode types compared to the state of the art brass tube electrode, which clearly establishes the advancement of the present invention over the prior art for fast hole drilling EDM applications. The most surprising result of the analysis is the performance of the -phase brass coated electrode GBT400 sample 340. More specifically, the GBT400 sample 340 that had received a second heat treatment at finish size resulted in a fully recrystallized microstructure. It has been suggested that annealed microstructures in the wire EDM application posses the fastest cutting speeds (see EDM Today Magazine, Volume 24, Issue 3, pg 34) but the common practice in the wire EDM application is to use fully hardened wires primarily because of their mechanical stability in automatic wire threading operations.

[0070] The rotating aspect of the tube electrode in fast hole drilling also benefits from a similarly hard, as-drawn microstructure as in the wire application. The annealed microstructure of GBT400 was considered an acceptable risk to take in order to conveniently demonstrate the versatility the diffusion anneal process as applied to fast hole drilling electrode construction. Using a heat treatment to form a -phase layer or a duplex / phase layer prior to tube reduction in Step 3 would be a desirable process sequence.

[0071] The diffusion anneal process for constructing brass tube electrodes provides a myriad of potential metallurgical combinations for improved EDM milling tube electrodes to take advantage of the inherent physical and chemical properties of the coat specie in addition to the physical state resulting from the processing of the coating during tube fabrication.

[0072] What have been described above are examples of the present invention. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the present invention, but one of ordinary skill in the art will recognize that many further combinations and permutations of the present invention are possible. Accordingly, the present invention is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims.