MANUFACTURING DEVICE FOR ELECTROCHEMICAL MACHINING OF A COMPONENT, IN PARTICULAR A TURBINE COMPONENT, METHOD FOR ELECTROCHEMICAL MACHINING OF A COMPONENT, AND COMPONENT

Abstract

The invention relates to a manufacturing device for the electrochemical machining of a component, in particular a turbine component, wherein the manufacturing device comprises at least one machining device, which is set up to remove material of the component in accordance with a predetermined electrochemical machining method. It is provided that the manufacturing device comprises at least one cleaning device, which is set up to spray jets of the electrolyte solution onto the component in accordance with a predetermined jet-spraying method in order to remove a residue layer formed on the component during the predetermined electrochemical machining method.

Claims

1. A manufacturing device for the electrochemical machining of a turbine component, wherein the manufacturing device comprises at least one machining device, which removes material of the component in accordance with a predetermined electrochemical machining method, wherein the manufacturing device comprises at least one cleaning device, which sprays jets of an electrolyte solution onto the component in accordance with a predetermined jet-spraying method to remove a residue layer formed on the component during the predetermined electrochemical machining method.

2. The manufacturing device according to claim 1, wherein the manufacturing device shifts in position and/or rotates the component and/or the machining device to arrange the component in a predetermined material removal position in relation to the machining device.

3. The manufacturing device according to claim 1, wherein the manufacturing device shifts in position and/or rotates the component and/or the cleaning device in order to arrange the component in a predetermined cleaning position in relation to the cleaning device.

4. The manufacturing device according to claim 1, wherein the cleaning device comprises at least one jet-spraying nozzle, which sprays jets, at least one jet, of the electrolyte solution on predetermined regions of the component.

5. The manufacturing device according to claim 4, wherein the cleaning device comprises at least two jet-spraying nozzles, wherein the jet-spraying nozzles are aligned with respect to each other wherein the jet-spraying directions of the respective jets differ from each other.

6. The manufacturing device according to claim 1, wherein the manufacturing device rotates the component during the predetermined electrochemical machining method and/or during the predetermined cleaning method around at least one predetermined axis in space.

7. The manufacturing device according to claim 1, wherein the machining device, the cleaning device, and the component are arranged in a machine chamber of the manufacturing device.

8. The manufacturing device according to claim 1, wherein the cleaning device changes the alignment or positioning of at least one of the jet-spraying nozzles.

9. The manufacturing device according to claim 1, wherein the electrolyte solution is fed to the cleaning device and to the machining device from the same tank.

10. The manufacturing device according to claim 1, wherein the manufacturing device manufactures the component in accordance with a predetermined manufacturing method in a plurality of method steps, wherein the manufacturing device arranges in one of the method steps, the component in the material removal position and machines a respective region of the component in accordance with the predetermined machining method and, subsequently, arranges the component in the cleaning position and machines the respective region of the component in accordance with the predetermined cleaning method.

11. A method for the electrochemical machining of an aircraft component, wherein, by way of a machining device of a manufacturing device in accordance with a predetermined electrochemical machining method, material of the component is removed, wherein, by way of a cleaning device of the manufacturing device, an electrolyte is sprayed in jets onto the component in accordance with a predetermined jet-spraying method in order to remove a residue layer formed on the component during the predetermined electrochemical machining method.

12. A component manufactured in accordance with the method according to claim 11.

13. The component according to claim 12, wherein the component (3) is configured and arranged as a blisk.

Description

BRIEF DESCRIPTION OF THE DRAWING FIGURES

[0032] Further features of the invention ensue from the claims, the figures, and the descriptions of the figures. The features and combinations of features described above as well as the features and combinations of features mentioned below in the description of the figures and/or solely in the figures can be used not only in the respectively presented combination, but also in other combinations, without leaving the scope of the invention. Accordingly, the invention also comprises embodiments that are not shown and explained explicitly in the figures, but which ensue and can be produced from the explained embodiments by separate combinations of features. Also to be regarded as disclosed are embodiments and combinations of features that, accordingly, do not have all features of a claim as originally formulated. Beyond this, embodiments and combinations of features, in particular through the embodiments presented above, that go beyond the combinations of features presented in the back-references of the claims or deviate from them are to be regarded as disclosed. Herein:

[0033] FIG. 1 shows a schematic illustration of a manufacturing device according to the invention for the electrochemical machining of a component; and

[0034] FIG. 2 shows another schematic illustration of the manufacturing device according to the invention; and

[0035] FIG. 3 shows a schematic illustration of a sequence of the method according to the invention for manufacturing a component.

DESCRIPTION OF THE INVENTION

[0036] FIG. 1 shows a schematic illustration of a manufacturing device for the electrochemical machining of a component. The manufacturing device 1 can have a machining device 2, which can be set op to remove a material of a component 3 in accordance with a predetermined electrochemical machining method. In particular, the component 3 can be an element of a turbine, such as, for example, a blisk. For removal of the material, it can be provided that the component 3 is arranged in a predetermined material removal position 4 inside of a machine chamber 5 of the manufacturing device 1. The predetermined material removal position 4 can describe a predetermined geometric relation between the component 3 and the machining device 2. It can be provided that, during the machining method, a region 6 of the component, which may involve, for example, a blade of the component 3, is arranged in the machining device 2. During the predetermined machining method, it can be provided that the machining device 2 is poled as the cathode and the component 3 is poled as the anode, while an electrolyte solution 7 is fed through a gap between the component 3 and the machining device 2 in order to wash away the material from the component 3. It can be provided that the component 3 is arranged on an actuator device 8, which can be set up to change the position of the component 3 by way of rotating or shifting the component 3. The machining device 2 can also have a holding device 9, which can be fixed in position or which can change the position of the machining device 2.

[0037] The manufacturing device 1 can have a collecting basin, which can be a tank 10 for collecting and/or providing the electrolyte solution 7. During the machining method, the electrolyte solution 7 can be collected in the tank 10 of the manufacturing device 1. After the machining of the component 3 or at least of the region 6 of the component 3, it may be necessary to clean the component 3 or at least the region 6 of the component 3 in order to remove a residue layer that has formed on the component 3 or on the region 6 of the component 1 during the machining method. In order to make this possible, the manufacturing device 1 can have a cleaning device 11, which can have at least one jet-spraying nozzle 12. The cleaning device 11 can be arranged on a holding device 13, which can bear the cleaning device 11 in fixed position or which can be capable of moving it or rotating it in the machine chamber 5 of the manufacturing device 1. The cleaning device 11 can be provided to clean the component 3 or the region 6 of the component by means of jet-spraying the region to be cleaned. As jet-spraying agent, it is possible to use the electrolyte solution 7, which, for example, can be taken from the collecting basin or from another possible common tank 10, so that the cleaning device 11 and the machining device 2 can be fed from the same source.

[0038] FIG. 2 shows another schematic illustration of a manufacturing device for the electrochemical machining of a component. Shown is the component 3 in a predetermined cleaning position 14. The cleaning position 14 can describe a predetermined geometric position of the component 3 in relation to the cleaning device 11. In order to attain the cleaning position 14, it can be provided that the component 3 and/or the cleaning device 11 are shifted in position. The cleaning device 11 can be shifted in position, for example, by way of holding device 13, whereas the component 3 can be shifted in position, for example, by way of the holding device 8. If the component 3 is situated in the predetermined cleaning position 14, the cleaning device 11 can emit jets 15 of the electrolyte solution 7 through the jet-spraying nozzles 12, said jets being capable of impinging on the region of the component 3. The respective jet 15 can comprise the electrolyte solution 7 and preferably impinge perpendicularly on the region 6 to be cleaned. In order to be able to clean a plurality of surfaces at different angles, it can be provided that the cleaning device 11 has a plurality of jet-spraying nozzles 12, which are set up to guide the jets 15 in respective different jet-spraying directions onto the component 3 or the region 6. The impinging jets 15 of the electrolyte solution 7 enable the residue layer that may have formed during the machining method to be removed from the component 3 as long as it is still fluid. It can be provided that the manufacturing device 1 is set up to manufacture the component 3 in accordance with a predetermined manufacturing method serially in a plurality of method steps. In order to enable a cleaning of the individual regions 6 in a timely manner, it can be provided that, in succession, a predetermined number of blades are machined as individual regions 6 of the component 3 by the machining device 2. It can be provided that, after the removal of the material for a predetermined number of blades, the component 3 is shifted in position into the predetermined cleaning position 14 in order to clean the blades 6 that have just been machined during the machining method. After the blades in the respective method step have been cleaned, it can be provided that, in the next method step, the component 3 is shifted in position into the predetermined material removal position 4 in order to machine the next blades 6 of the component 3.

[0039] FIG. 3 shows a schematic illustration of a sequence of a method for manufacturing a component. It can be provided that, in a first step S1, the component 3 is arranged in the manufacturing device 1. In a step S2, the component 3 can be shifted in position by way of the holding device 8 to a predetermined material removal position 4. Subsequently, material of the component 3 can be removed in accordance with the predetermined machining method by the machining device 2 of the manufacturing device 1. Residues may thereby deposit on the component 3. After conclusion of the material removal, it can be provided that the component 3 is shifted in position to a predetermined cleaning position 14 in order to clean the component 3 by the cleaning device 11. It is possible here for the jet-spraying nozzles 12 of the cleaning device 11 to emit jets 15, as a result of which the residues can be removed. It can be provided that the manufacture of the component 3 occurs in a plurality of steps and another region 6 of the component 3 is machined and cleaned in a next step. For this purpose, the method step S2 and the method step S3 can be repeated for the corresponding other regions 6. It can be provided that, after machining all of the regions 6, the manufacturing method is concluded and, in a step S4, the component 3 can be removed from the manufacturing device 1.

[0040] In accordance with the prior art, the processes of manufacturing/machining and cleaning are clearly separate from one another and operations are conducted serially. A hybrid or mixed process is not known. Nor are the equipment and operating agents required for this known.

[0041] In electrochemical metal machining, the material component 3 undergoes dissolution in terms of its microstructure in an individual manner. This occurs by a redox reaction of the electrolyte solution 7 with the anode material of the component 3. As the reaction outcome of this chemical reaction, which is necessary for the goal-oriented removal of material, a residue layer adheres to all process-related surfaces. The finished machined component surfaces are also coated with the mentioned deposit. During the manufacturing process, the residues are still nearly fluid, but, after prolonged waiting of longer than 1 hour, the residues dry and a hard crust of residue products, which is undesirable, is formed on the workpiece. According to the prior art at the present time, the complete workpiece, such as, for example, a blisk, is prepared in finished form and, subsequently, is serially shot-peened 15 in another technical department in order to remove the hard residue layer. Easier cleaning variants have not proven to lead to the desired goal, because the residue layer is very hard and strongly adhesive.

[0042] Instead of a serial machining and a subsequent cleaning process, a hybrid process has proven to be very helpful and time-saving. Thus, a cleaning device 11 is integrated in the manufacturing device 1 and is fastened permanently to the machine housing and can be positioned relative to a machine coordinate system.

[0043] The goal of the process is that, after the manufacture of a defined number of regions 6 of the component, which, for example, can be individual blade elements, a cleaning method proceeds automatically in the manufacturing device 1 without any effort for a renewed setup. In terms of number, 1 to 10 regions 6 can be involved, for example. For the cleaning method, the manufacturing device can move the workpiece to a predetermined cleaning position 14 in a coordinate system of the cleaning device 11 and then the cleaning method can be commenced immediately. On account of the short drying times, it is possible to use as cleaning medium the normal electrolyte solution 7 from the machine chamber 5 and, accordingly, no other media are required. Thus, the residues, which do not adhere strongly, are washed away and, subsequently, the manufacturing method can be continued.

[0044] The hybrid approach spares efforts involved in renewed setup and logistics, because the process step of shot peening can be entirely dispensed with for the cleaning. The cleaning device 11 must be adapted to the geometric requirements of the workpiece, so that the jets 15 impinge on the cleaning surfaces as orthogonally as possible.