Electrical discharge machining
09707637 ยท 2017-07-18
Assignee
Inventors
Cpc classification
B23H7/30
PERFORMING OPERATIONS; TRANSPORTING
B23H7/26
PERFORMING OPERATIONS; TRANSPORTING
B23H7/38
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23H1/10
PERFORMING OPERATIONS; TRANSPORTING
B23H7/30
PERFORMING OPERATIONS; TRANSPORTING
B23H7/38
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method for electrical discharge machining a workpiece includes the steps of: presenting an elongate electrode to the workpiece with a spark gap therebetween; flowing a dielectric fluid in the gap; eroding the workpiece by electrical discharge between the tip of the electrode and the workpiece; displacing the electrode in a direction aligned with the long axis of the electrode to maintain the gap as the electrode wears and the workpiece is eroded; and simultaneously with the displacement, producing vibratory movement of the electrode, the vibratory movement being aligned with the long axis of the electrode.
Claims
1. A method for electrical discharge machining a workpiece including the steps of: presenting an elongate electrode to the workpiece with a spark gap therebetween, flowing a dielectric fluid to the gap, eroding the workpiece by electrical discharge between the tip of the electrode and the workpiece, using a servo system to displace the electrode in a direction aligned with the long axis of the electrode to maintain the gap as the electrode wears and the workpiece is eroded, and simultaneously with the displacement, using the servo system to produce vibratory movement of the electrode, the vibratory movement being aligned with the long axis of the electrode; wherein the servo system has a frequency response of at least 1 kHz for displacing the electrode to maintain the gap.
2. A method according to claim 1, wherein the electrode has an axial bore, and the dielectric fluid flows through the bore and into the gap.
3. A method according to claim 2, wherein pulsating jets of the fluid are sent along the bore to the gap, the pulsating jets having a pulse frequency which is the same as the frequency of the vibratory movement of the electrode.
4. A method according to claim 1, wherein the vibratory movement has a frequency of up to 500 Hz.
5. A method according to claim 1, wherein the vibratory movement has a frequency of more than 50 Hz.
6. A method according to claim 1, wherein the dielectric source supplies the dielectric fluid to the gap at a pressure of from 70 to 100 bar.
7. A method according to claim 1, wherein a plurality of the electrodes are simultaneously presented to the workpiece.
8. An electrical discharge machining apparatus including: an elongate electrode, a servo system which displaces the electrode relative to, in use, a workpiece, the displacement being in a direction aligned with the long axis of the electrode, and maintaining a spark gap between the electrode and the workpiece as the electrode wears and the workpiece is eroded by the electrode, a dielectric source which produces a dielectric fluid flow in the gap, and the servo system being configured to produce, simultaneously with the displacement, vibratory movement of the electrode, the vibratory movement being aligned with the long axis of the electrode; wherein the servo system has a frequency response of at least 1 kHz for displacing the electrode to maintain the gap.
9. An apparatus according to claim 8, wherein the electrode has an axial bore, and the dielectric source flows the dielectric fluid into the gap along the bore.
10. An apparatus according to claim 9, wherein the dielectric source includes a reservoir for the dielectric fluid, and a vibration source is operationally connected to the reservoir, such that, on activation of the vibration source, pulsating jets of the fluid are sent from the reservoir, along the bore and to the gap simultaneously with the production of vibratory movement of the electrode.
11. An apparatus according to claim 10, wherein the electrode enters the reservoir through an aperture having a seal formation which grips the electrode to prevent leakage of dielectric fluid from the reservoir at the aperture, the seal formation being configured such that its grip on the electrode is activated by the pressure of the dielectric fluid in the reservoir.
12. An apparatus according to claim 11, wherein the vibration source, on activation, vibrates a piston that generates corresponding pressure pulses in the dielectric fluid of the reservoir, the axial bore of the electrode opening to the reservoir such that the pressure pulses produce the fluid jets.
13. An apparatus according to claim 12, wherein the electrode is connected to the piston such that the piston and electrode vibrate in unison.
14. An apparatus according to claim 8 wherein the servo system includes a linear induction motor.
15. An apparatus according to claim 8 including one or more linear actuators which provide the vibration source and which combine with a separate servomotor to provide the drive mechanism, the linear actuators being coupled to the electrode to produce the vibratory movement of the electrode.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which:
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DETAILED DESCRIPTION
(15) Removal of debris during HSEDM is important in order to achieve appropriate machining speeds and consistency. Debris is removed by the dielectric flushing out debris in the time between the sparks. This process is shown schematically in
(16) As illustrated in
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(18) However, interruptions caused by inadequate removal of debris and consequent short circuiting can limit HSEDM effectiveness.
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(20) A linear induction servomotor 101 is coupled to a head carriage 103 by means of a motor rod 102. The head carriage is in turn mounted to a linear rail 115 (although in other embodiments, more than one linear rail may be used, or different types of linear guides can be employed, including linear air bearings). When the linear servomotor is activated, linear motion is thereby imposed on the head carriage.
(21) An electrical connector 118 and a pneumatic chuck 104 are provided on the head carriage 103. The connector 118 is connected to an electrical power supply (omitted in
(22) The tool holder 106 has an electrode cartridge 105. A noseguide assembly 111 carrying a noseguide 110 is coupled to a static part 114 of the apparatus by means of a chuck 112. The electrodes 108 and high-pressure dielectric fluid are contained within the electrode cartridge. The electrodes pass under clamps 107, 109 and out through the noseguide. The clamp 107 is mounted beneath the electrode cartridge and consists of a bar, with a rubber pad, that is pneumatically applied to nip the electrodes during the drilling cycle. The clamp 109 is mounted on the noseguide assembly and consists of a bar, with rubber pad, that is pneumatically applied to nip the electrodes during the electrode reefed cycle.
(23) Compressed air is supplied to clamps 107, 109 through respective connectors 116, 113. High-pressure dielectric fluid is fed to the electrode cartridge 105 and the noseguide 110 through respective connectors 119 and 120. Thus connectors 116, 119 are on the head carriage 103, while connectors 113, 120 are on the static part 114 of the apparatus. The tubular electrodes are bathed in dielectric fluid in a reservoir contained within the electrode cartridge 105 so that the dielectric can flow both through and outside the electrodes. A high-pressure (e.g. 70-100 bars) pump (omitted in
(24) The linear induction servomotor 101 is capable of producing acceleration of up to 50 g in a mass of up to 10 Kg and can provide positional accuracy as small as 1 micron. In contrast to conventional rotary motors, linear induction motors convert electrical energy directly into linear movement, producing a straight-line force along the length of the motor. The linear servomotor is thus able simultaneously to displace the electrodes 108 in a direction aligned with their long axes to maintain the spark gap as the electrode wears and the workpiece is eroded, and to produce vibratory movement of the electrodes, the vibratory movement being aligned with the long axes of the electrodes.
(25) A control system for the apparatus of
(26) As machining occurs (i.e. high frequency sparks remove material from both electrodes 108 and workpiece 127), the linear servomotor 101 displaces the tool holder 106 to which the electrodes are mounted at the displacement speed 125 to keep constant the spark gap 130 between electrodes and workpiece. A meter 131 continuously measures the mean gap voltage, which is compared with the servo reference voltage 126 by a numerical control (NC) unit 132. The tool holder 106 is moved downward if the mean gap voltage is higher than the reference voltage and upward when the mean gap voltage is lower than the reference voltage. The linear servomotor has a frequency response in excess of 1000 Hz, i.e. due to the dynamic characteristics of the linear servomotor and its control system, the servomotor can respond to changes in the spark gap within 0.001 sec.
(27) Key process variables (such as frequency and amplitude of vibration, speed of displacement and EDM generator parameters) can be varied during the drilling process according to the depth of holes being drilled. This variation may be controlled by a program executed by the computer 123, together with the NC unit 132. An alternative approach that can be used to change key process variables during the drilling process is to use sensors to measure spark gap conditions in a closed-loop system e.g. combined with artificial intelligence techniques such as neural network or fuzzy logics. Such an approach could facilitate dynamic optimisation of the process variables.
(28) The linear servomotor 101 can induce vibrations in the electrodes of up to 200 Hz with peak to peak amplitudes of up to 100 microns, and a resolution smaller than 0.1 microns. These vibrations induce corresponding vibrations in the dielectric fluid which can improve removal of debris from the spark gap. Furthermore, the servomotor positional accuracy of 1 micron facilitates accurate control of the spark. In addition, the high frequency vibration creates gaps between the electrode surfaces and the walls of the drilled hole which minimise the occurrence of arcing.
(29) More specifically, cooling holes in turbine blades can have diameters as small as 0.38 mm and length-to-diameter-ratios of up to 80:1. The diameter of an electrode employed to drill 0.38 mm holes is usually 0.33 mm. If there is a requirement to drill a hole with diameter of 0.38 mm and length of 30 mm, the distance from the tip of the electrode to the noseguide will be 30 mm at hole breakthrough. Such a slender electrode can tend to tilt and touch the sidewall of the hole during the drilling process, provoking short-circuits and process interruption. Another problem associated with the drilling of deep holes with small diameters is the removal of debris from the spark gap. This can be difficult even when high-pressure dielectric fluid (of up to 100 bars) is employed. The accumulation of debris can provoke arcing and increase cycle times. These problems become more critical when multi-electrode drilling operations are carried out, as the apparatus has just one servomotor to control a plurality of spark gaps.
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(33) Thus the vibration of the electrodes improves flushing and reduces short-circuits, and, as a result, the servomotor can move downwards at faster speeds.
(34) Drilling trials were carried out using a multi-electrode tool with capacity to hold 18 tubular electrodes. The diameter of the electrodes was 0.31 mm and these were used to cut (in a single pass) 18 holes with a length of 4 mm. A Design of Experiments fractional factorial approach was used to perform the experiments and analyse the results. The factors used in the design are shown in the table below. The factor Vibration refers to the vibration produced in the electrode. The lower level (1) of vibrations means that tests were carried out without vibrations, whereas the higher level (+1) means that the tests were carried out with vibrations. Servomotor Speed refers to the velocity with which the servomotor advances to keep the spark gap constant. Gap Voltage refers to the reference voltage, which is proportional to the spark gap size, i.e. a Gap Voltage at the higher level means that the size of the spark gap is higher than at the lower level.
(35) TABLE-US-00001 LEVEL FACTOR I II Vibration 1 +1 Servomotor Speed 1 +1 Gap Voltage 1 +1
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(38) Further drilling trials were carried out to produce additional interaction plots.
(39) The HSEDM apparatus described with reference to
(40) An electrical connector 321 and a pneumatic chuck 305 are provided on the head carriage 304. The electrical connector is connected to an electrical power supply (omitted in
(41) The tool holder 308 has an electrode cartridge 307. A noseguide assembly 314 carrying a static noseguide 313 is coupled to a static part 317 of the apparatus by means of a chuck 315. The electrodes 311 and high-pressure dielectric fluid are contained within the electrode cartridge. The electrodes pass under clamps 310, 312 and out through the noseguide. The clamp 310 is mounted beneath the electrode cartridge and consists of a bar, with rubber pad, that is pneumatically applied to nip the electrodes during the drilling cycle. The clamp 312 is mounted on the noseguide assembly and consists of a bar, with rubber pad, that is pneumatically applied to nip the electrodes during the electrode reefed cycle.
(42) Compressed air is supplied to clamps 310, 312 through connectors 319, 316. High-pressure dielectric fluid is fed to the electrode cartridge 307 and the noseguide 313 through connectors omitted in
(43) Two linear actuators 322 are assembled in a vibration plate 306 mounted to the tool holder 308 (in other embodiments only one linear actuator, or more than two linear actuators can be employed).
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(45) The linear actuators 322 produce oscillations 332 in the moving section 325 of the vibration plate 306, where the pressure cap 309 and clamp 310 are mounted. The movement of the vibration plate induces vibrations (with frequencies of up to 500 Hz and peak-to peak amplitude up to 100 microns) in the electrodes 311. Moreover, the oscillations of the pressure cap 309 induce pressure pulses in the dielectric fluid 330 contained in the reservoir of the electrode cartridge 307. These pressure pulses produce high frequency pulsating jets 333 of dielectric fluid that are supplied to the spark gaps via the bores of the electrodes. Advantageously, the combined effects of the pumping action provided by electrode oscillations and the high frequency pulses of the dielectric jets greatly improve the flushing of debris from the spark gaps. Furthermore, the use of separate linear actuators to drive the electrode vibration facilitates the retrofitting of such actuators onto existing HSEDM apparatuses.
(46) A disadvantage of lead-screw servomotors is their typically low frequency response of about 30 Hz, which is not fast enough to respond to rapid changes to the spark gap. It is possible to increase the frequency response of lead-screw servos by increasing the pitch and/or rotational speed. However, this affects the positional resolution of the electrodes. Moreover, too high rotational speeds can cause the screw to whip or hit a resonant frequency causing uncontrolled vibrations and wild instability. However, by retrofitting a lead-screw servomotor with one or more linear actuators to drive electrode vibrations, the low frequency response can be side-stepped such that the retrofitted apparatus can be made to provide high frequency vibratory movement of the electrodes simultaneously with their displacement to maintain the spark gap. Also the dielectric fluid can be made to issue from the bores of the electrodes into the spark gaps as pulsed jets synchronised with the electrode vibration to further enhance debris removal.
(47) However, if screw resonance and whip can be avoided, by using e.g. appropriate software it is nonetheless possible to control a lead-screw servomotor to produce electrode vibrations superimposed on the linear motion of the electrodes without the use of additional linear actuators. Although the response time of such an arrangement will be relatively low, some benefits can be obtained, such as the ability to produce pulsating jets of dielectric fluid and improved removal of debris through a dielectric fluid pumping action.
(48) The apparatus of
(49) In an operational variant, the task of keeping constant the size of the spark gap can be shared between the linear actuators 322 and the lead-screw servomotor 301. More specifically, the linear actuators provide high positional precision and a high frequency response, but only allow a maximum stroke about 200 microns. Thus, as well as vibrating the electrodes 311, the actuators can be used to displace the electrodes to keep the spark gap constant up to the stroke limit of the actuators, whereupon the lead-screw servomotor re-feeds the electrodes. Indeed, a variant apparatus can have one or more linear actuators to provide electrode vibration and displacement, and a linear induction servomotor instead of a lead-screw servomotor to re-feed the electrodes.
(50) While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. For example, an apparatus can have just one electrode. Another type of electrode tool holder can produce electrode rotation during the drilling process. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.
(51) All references referred to above are hereby incorporated by reference.