ELECTROLYTIC POLISHING METHOD AND DEVICE AND METHOD FOR PRODUCING A CATHODE

Abstract

In a method and a device for electrolytically polishing inner surfaces of a recess in a workpiece made of metal, in particular a workpiece printed in three dimensions, provision is made that a cathode is introduced into the recess and polishes the inner surface of the recess using an electrolyte having a slow diffusion rate.

Claims

1. A method of electrolytically polishing an inner surface of a recess in a workpiece made of metal, characterized by the steps of: (A) immersing the workpiece in an electrolyte containing a salt, water and alcohol having a minimum weight proportion of from 20-70% per liter of electrolyte; (B) connecting the workpiece to a positive pole so that the workpiece forms an anode; (C) providing at least one cathode in the electrolyte and the recess; (D) providing a relative movement between the electrolyte and the workpiece; and (E) applying an electric voltage between the anode and the at least one cathode.

2. The method according to claim 1, characterized in that the workpiece consists of a nickel alloy, chromium alloy, or light metal.

3. The method according to claim 1, characterized in that a cathode is connected to a negative pole of a power source by an electric line and is inserted into the recess in the workpiece for treating the inner surface of the recess.

4. The method according to claim 3, characterized in that the cathode is formed to be flexible.

5. The method according to claim 3, characterized in that at least one electrically insulating spacer projects laterally from the cathode.

6. The method according to claim 5, characterized in that a plurality of spacers that are axially spaced from each other are provided on the cathode.

7. The method according to claim 5, characterized in that the cathode together with the spacer(s) is formed as a circular brush and the insulating spacers are projecting filaments or in that the cathode is an elongated body having a groove that is helical on its outer surface and transports electrolyte.

8. The method according to claim 5, characterized in that, after a first polishing step, the cathode is moved relative to the workpiece to expose a support portion at which the spacer was previously located opposite the workpiece, and carrying out a second polishing step for polishing the support portion.

9. The method according to claim 1, characterized in that the outer surface of the workpiece is polished simultaneously with the inner surface by applying the electrical voltage.

10. The method according to claim 1, characterized in that, in order to achieve the relative movement between the electrolyte and the workpiece, the electrolyte is pumped and flows past the workpiece and/or the workpiece is moved in the container receiving the electrolyte.

11. The method according to claim 1, characterized in that at least one cathode has a surface which is located opposite the workpiece and which is profiled.

12. The method according to claim 1, characterized in that the workpiece, and additionally the at least one cathode and/or a support structure forming an anode, is produced by a generative manufacturing method.

13. The method according to claim 12, characterized in that a workpiece is used on which the cathode and/or a support structure forming an anode is co-printed by the generative manufacturing method.

14. The method according to claim 13, characterized in that metal grains having diameters of from 20 to 60 m are used for printing.

15. The method according to claim 12, characterized in that, the support structure is configured as a support plate and during the electrolytic treatment, the workpiece is seated on the support plate which forms the anode.

16. The method according to claim 15, characterized in that a cathode for external treatment of the workpiece is fastened to the support plate by means of an electrically insulating mounting.

17. The method according to claim 1, characterized in that, during the treatment, the electrolyte has a maximum temperature of 20, and/or a pH of up to 6.8 or between 9 and 12.

18. The method according to claim 1, characterized in that the cathode is inserted into the recess and electrolyte is pumped into the gap between the cathode and the inner surface, of the workpiece opposite to it.

19. The method according to claim 1, characterized in that the cathode is introduced into the recess more deeply and less deeply in relation to the recess by means of a motor drive or manually.

20. The method according to claim 1, characterized in that the cathode has a side which faces the workpiece and which, prior to the treatment of the workpiece, has a constant gap with respect to the side of the workpiece which faces it, and manufactured after the treatment of the workpiece.

21. A method of manufacturing a cathode for the electrolytic treatment of a workpiece, the cathode having a side facing the workpiece to be treated characterized by the steps of: (a) determining an outer geometry of the cathode at least in the region of the side facing the workpiece, wherein electric and/or magnetic fields that are present between the cathode and the workpiece during the electrolytic treatment are determined and the outer geometry of the cathode is determined taking into account a constant current density on that side of the workpiece which faces the cathode, and (b) generating the cathode by a generative manufacturing method on the basis of the outer geometry determined.

22. A device for electrolytic anodic polishing of an inner surface of a recess in a workpiece made of metal, comprising a container filled with an electrolyte, the electrolyte containing a salt, an alcohol having a minimum weight proportion of from 20 to 70%, and water, a holding device for the workpiece, a cathode which is movable relative to the recess and has an electrical insulation in sections on its outside and is connected to a power source by a cable, a drive being provided for generating a relative movement between the electrolyte present in the recess and/or the cathode, on one hand, and the workpiece, on the other hand.

23. The device according to claim 22, characterized in that a laterally flexible cathode is provided, portions of which are provided with an electrical insulation projecting on the outside and forming a spacer.

24. The device according to claim 22, characterized in that, in addition to the cathode introduced into the recess, at least one external cathode is provided for polishing the outer surface of the workpiece.

25. The device according to claim 22, characterized in that a change holder is provided for fixing the cathode, the change holder being equipped with a power and/or electrolyte connection and/or a drive for moving the cathode.

26. The method according to claim 1, characterized in that the workpiece is a metallic workpiece produced by a generative manufacturing method.

27. The method according to claim 12, characterized in that the workpiece and additionally the at least one cathode and/or a support structure forming an anode, is produced using laser sintering.

28. The method according to claim 18, characterized in that the electrolyte is pumped into the gap through a separate electrolyte conduit connected to the recess.

29. The device according to claim 22 for the electrolytic anodic polishing of an inner surface of a recess in a workpiece made of metal and printed in three dimensions.

Description

[0068] Further features and advantages of the invention will be apparent from the description below and from the accompanying drawings, to which reference is made and in which:

[0069] FIG. 1 shows a cross-section taken through a schematically illustrated device according to the invention for carrying out the method according to the invention;

[0070] FIGS. 2 to 4 show different embodiments of a cathode employed in the device according to the invention and in the method according to the invention; and

[0071] FIG. 5 shows a schematic side view of a further embodiment of the device according to the invention.

[0072] FIG. 1 shows a device for the electrolytic anodic polishing, the device having a container 10 which is filled with an electrolyte 12. A workpiece 14 is completely immersed in the electrolyte 12 by means of a holding device 16 and can be reciprocated along a linear guide 18 by means of a motor 20. The workpiece 14 has a recess, here in the form of an arcuate, curved hole. The recess is defined by an inner surface 22.

[0073] The workpiece 14 is connected to a power source 26 by a cable 24 and acts as an anode. One or more cathodes 28, 30 are also connected to the power source 26 by cable(s) 32. The cathodes 28 are intended for treating or machining the outer surface of the workpiece and in the present case are plate-shaped or profiled (see vertical cathode 30). The shape of the cathodes 28 does not need to correspond to the desired or existing outer shape of the workpiece 14 in the area where the cathodes 28 are positioned opposite the workpiece 14.

[0074] The cathode 30 is flexible and, in the non-deflected position, it is preferably linear (see FIGS. 2 to 4). When it is inserted into a non-linearly extending recess, however, it can adapt to it.

[0075] To prevent contact of the cathode 30 with the inner surface 22 of the recess, a plurality of electrically insulating spacers 34 are attached to the cathode 30. In the embodiment according to FIG. 2, these spacers 34 are filaments which are attached to the wire-type cathode 30 by clamps like in a circular brush.

[0076] In the embodiment according to FIG. 3, for example, block-like or cylindrical spacers 34 are fitted on, injection-molded on, glued on or otherwise attached to the flexible cathode 30.

[0077] The cathode 30 according to FIG. 4 is also laterally pliable and coated with spacers 34 in the form of an insulation, resulting in a kind of drill shape. The insulation has a helical shape so that a helical, electrolyte-carrying groove 36 is obtained between the threads, with the cathode 30 exposed in the base of the groove.

[0078] The electrolyte contains 50 g to 400 g salt per liter of electrolyte (preferably 150 g to 400 g), in particular an alkali salt, alcohol, in particular polyhydric alcohol such as glycol or glycerol, with a maximum weight proportion of from 20 to 70% per liter of electrolyte, and water as the balance. In addition, halogens may also be contained, in particular with a content of up to 100 g per liter of electrolyte.

[0079] The pH of the electrolyte is either a maximum of 6.8 or in the range between 9 and 12.

[0080] The electrolyte is typically brought to a temperature of 30 C. maximum, in particular 15 C., for treatment. The process temperature is in particular in the range of from 7 to 15 C.

[0081] The workpiece is preferably a metal workpiece printed in three dimensions, with metal grains that are joined together by laser sintering, for example, and have diameters of from 20 to 60 m. This means that on its outer surfaces as well as on the inner surface 22, the workpiece, expressed in a somewhat exaggerated way, is configured like an uncut polystyrene body consisting of numerous beads.

[0082] To polish the outer surfaces and the inner surface 22, the workpiece is pulled back and forth through the electrolyte 12 by the motor drive 20. The cathodes 28 are moved along with it because they are connected to the holding device 16 by means of coupling elements illustrated in dashed lines.

[0083] The cathode 30 is placed in the recess in advance. The spacer 34 allows electrolyte 12 to flow past it to the end of the recess on the workpiece side. For this purpose, for the spacers 34 according to FIG. 3, for example, axial grooves are provided on the outer shell surfaces of the spacers 34.

[0084] A current, for example a pulsating current, is applied at a voltage of 10 V to 40 V and a current intensity between 0.0003 A/mm.sup.2 and 0.01 A/mm.sup.2. Depending on the material of the workpiece and its initial roughness, the application time of the current is 30 s to 1200 sec.

[0085] Since in the region of the recess, the electrolyte 12 does not have an optimum effect between the recess and the spacers 34, especially as far as FIG. 3 is concerned, the cathode 30 is first brought into a certain position and, after a certain application or exposure time, is slightly shifted axially. After the polishing has previously taken place during a first polishing step between the spacers 34, these spacers 34, after the adjustment, are then shifted to the previously polished areas, so that the previous support portions are polished.

[0086] For uniform polishing, it may be useful to make the distances between neighboring spacers 34 so as to be the same as the length of the spacers, so that the cathode is shifted by the length of a spacer 34 between the polishing steps.

[0087] Movement of the cathode 30 may be effected manually, which, however, is primarily the case if the workpiece 14 is not moved in the electrolyte 12 by motor, but is stationary. Alternatively to this, a movement of the cathode 30 by motor may be useful.

[0088] To this end, FIG. 1 schematically shows a change holder 38 provided for fixing the cathode 30, which is provided with a current and/or electrolyte connection. A quick-change system in the change holder 38 allows new or other cathodes 30 to be inserted quickly. Furthermore, the change holder 38 may include a drive 39 for moving the cathode 30. For example, the change holder 38 is mounted to the holding device 16 and moves the cathode 30 in steps or slowly continuously in the recess.

[0089] The cathode 30 shown in FIG. 4 is caused to rotate so that the complete inner surface can be treated here as well and the spacer 34 only temporarily shields support portions on the inner surface 22.

[0090] For optimum treatment, it may be useful, in addition to or as an alternative to moving the workpiece 14, to set the electrolyte itself in motion, for example by means of a circulation pump 40 which has an inlet on one side of the container 10 and an outlet on the opposite side, so that a uniform flow is achieved in the container 10.

[0091] There should be a flow of electrolyte in the recess as well. This may be effected, for example, by reciprocating the cathode 30 or causing it to rotate (see FIG. 4), on the one hand, or by having a separate pump for electrolyte that is seated at the inlet of the recess. Supplying or carrying of electrolyte in the recess may also be done through a hollow cathode 30.

[0092] In the case of 3D products, roughnesses of about RZ 60 are reached for the grain diameters mentioned above, the roughnesses being brought to surface qualities of RZ 3 to 4 by the polishing process.

[0093] The device and the method are used in particular for 3D-printed parts for aircraft, such as engine parts, with cooling ducts incorporated during printing. It is also possible by the above-mentioned machining to remove support surfaces or support ribs that were produced during 3D printing or to selectively create openings in normally inaccessible inner ribs so that flow channels are formed here.

[0094] But the cathode 30 may also be co-printed in 3D printing, so that it is connected to the inner surface 22 e.g. only via thin supporting walls that have to be removed, and is then exposed and only needs to be coupled to the cable 2. Furthermore, it is conceivable that the supporting walls are made of an insulating material and therefore remain in existence during polishing.

[0095] The cathode 28 may also be manufactured by a generative method. For example, it is possible to manufacture the cathode 28 jointly with the workpiece 14.

[0096] In the case of workpieces having edges, there is an increased charge density in the region of the edges during the electrolytic treatment. The cathode 28 can be customized for any desired outer geometry of the workpiece. For this purpose, a 2D or 3D simulation program is used in which the electrolytic treatment is also taken into account, i.e. electric and/or magnetic fields occurring later during the later treatment of the workpiece are simulated. A constant current density between the facing sides of the cathode and of the workpiece is further specified as a prerequisite in the simulation program. Once the side of the cathode facing the workpiece has been determined, the cathode can be manufactured using a generative manufacturing method based on the outer geometry ascertained in the simulation program. A cathode produced in this way is used in particular for the method described earlier and below.

[0097] In electrolytic treatment methods, the connection of the anode, more precisely the anode contact, to the workpiece can be problematic. Here, black spots may appear after the treatment. In order to avoid this and also to realize an effective treatment of the workpiece, the anode may be produced together with the workpiece by a generative manufacturing method, for example laser sintering. In this case, the anode is a so-called support structure, for example a support plate, which is then connected to the current source. Black spots on this support structure are not a disadvantage because the support structure is removed after treatment of the workpiece, in particular by spark erosion.

[0098] Furthermore, a plurality of workpieces can be produced on the same support structure and then electrolytically treated.

[0099] FIG. 5 shows a support plate 50 which was printed together with the workpiece 14 or, in more general terms, produced generatively. While the support plate 50 and the workpiece 40 are one part, only the support plate 50 is illustrated in hatched form for better distinguishability of the two sections, whereas the workpiece 14 is drawn as a block. In reality, the two sections transition into each other in one piece.

[0100] However, the support plate 50 does not necessarily have to be in the form of a plate; it may quite generally have any desired shape and constitute a support structure.

[0101] A singular workpiece 14 on the support plate is shown here as an example only. Preferably, a plurality of workpieces 14 are on the same support plate 15.

[0102] The lower side of the support plate 50 fully rests over its entire surface on a tool-side, multi-part holding device. The holding device comprises an electrically insulating base plate 52, in which electrical, spring-loaded contact pins 54 are guided. The contact pins 54 are connected to the power source 20 via lines. A bearing plate 56 below the base plate 52 forms the holding device together with the base plate 52. FIG. 5 shows a plurality of cathodes 28 for external treatment. These cathodes 28 are generatively produced simultaneously or separately from the workpiece 14, in particular in order to ensure a uniform gap 58 or specified gap 58 between their side 60 facing the workpiece 14 and the workpiece 14.

[0103] The cathodes 28 may be mounted via electrically insulating mountings 62 in openings produced in the support plate 50, so that releasable plug connections are obtained.

[0104] FIG. 5 also shows the recess to be treated in the workpiece 14 and the cathode 32 inserted into it. The cathode 32 is mounted in an electrically insulating cathode receptacle 64, which in turn is attached to the holding device 16.

[0105] Electrolyte from a second container 66 is pumped directly into the container 10 through a line 70 by means of a pump 68, on the one hand, and, furthermore, is pumped directly into the recess through a line 72, a connection 74 and a duct inside the cathode 32. This results in a separate electrolyte line into the recess.

[0106] The ratio of water activity to relative moisture (the so-called aw value) is set in the range of 25-70%, ideally between 27-50%.