FLEXIBLE SPINDLE POLISHING
20250153307 ยท 2025-05-15
Inventors
Cpc classification
B24B57/02
PERFORMING OPERATIONS; TRANSPORTING
B24B37/02
PERFORMING OPERATIONS; TRANSPORTING
International classification
B24B37/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Precise surface treatment and finishing of an enclosed, non-linear channel through a 3-dimensional printed, additively manufactured or machined part or workpiece results from insertion of a grinding wheel on a flexible shaft and controlling an orbital movement though rotational speed, grit selection and fluid viscosity of a liquid medium in the channel. Drive logic rotates the flexible shaft for controlled rotation as the orbital movement or pattern achieves controlled contact with the interior channel surface. Rotational contact by the grinding wheel removes material based on a grit size, while the orbit is controlled through the rotation, viscosity and grit size for achieving uniform coverage of the interior surface. An internal geometry, typically circular or elliptical, is preserved while attaining a smooth surface through precise material removal resulting from the controlled orbit.
Claims
1. A polishing device for surface treatment of an interior surface of a conduit, comprising: a grinding wheel adapted for rotation; a flexible shaft attached to the grinding wheel; an abrasive surface geometry defined by an exterior of the grinding wheel; and a drive source responsive to drive logic for rotating the flexible shaft, the flexible shaft configured for a rotation speed for attaining an orbit of the grinding wheel based on the abrasive surface geometry.
2. The device of claim 1 wherein the abrasive surface geometry further comprises a grit size, the flexible shaft configured for a rotation speed for attaining the orbit of the grinding wheel based on the grit size of the abrasive surface geometry.
3. The device of claim 2 further comprising a fluid within the conduit, wherein the drive logic is configured for controlling the rotation speed based on at least the grit size and a viscosity of the fluid.
4. The device of claim 1, further comprising a fluid source, the fluid source configured to deliver a fluid having a viscosity and a density into the conduit, the orbit responsive to at least one of the viscosity and density for achieving a predetermined percentage of coverage of the interior surface based on consistent grinding wheel dynamics.
5. The device of claim 1 wherein the abrasive surface further comprises an abrasive height, the abrasive height indicative of a variation of the abrasive surface geometry based on the grit size.
6. The device of claim 5 wherein the abrasive surface geometry further comprises a distribution, orientation and patterning of an abrasive material adhered to the surface of the griding wheel.
7. The device of claim 1 wherein the rotation induces an elastic force in the flexible shaft, the elastic force resulting from a nonlinear path of the conduit, the orbit based on the abrasive surface geometry and the elastic force.
8. The device of claim 3 wherein the drive logic is further configured to generate, based on the rotational speed, grinding forces and hydrodynamic forces, the drive logic configured to ensure the grinding forces and hydrodynamic forces are unequal and opposed.
9. The device of claim 3 wherein the drive logic is further configured to generate, based on the rotational speed, grinding forces and hydrodynamic forces; and generate a net force acting in the direction of an intended orbital motion.
10. The device of claim 3 wherein the drive logic is further configured to generate, based on the rotational speed: a hydrodynamic force resulting from the viscosity and the grit size, the hydrodynamic force having components normal and outward to the interior surface, and tangential to the interior surface; and a grinding force having components inward and normal to the interior surface, and tangential to the interior surface and aligned with a rotation of the grinding wheel.
11. The device of claim 1 wherein the orbit defines a cyclic path around the interior of the conduit, the orbit having a radius less than a radius of the conduit.
12. The device of claim 11 wherein the orbit defines an irregular path, the irregular path based on at least the rotation speed, the abrasive surface geometry, a viscosity of fluid in the conduit, and a shape of the grinding wheel.
13. The device of claim 1 wherein the shape of the grinding wheel includes at least one of an ellipsoid with a circular cross section, sphere, fluted, finned and triangular with radiused edges.
14. The device of claim 1 wherein the conduit has an internal diameter of between 0.5-300 mm.
15. The device of claim 1 wherein the grit size defines the abrasive surface geometry with a grit height between 40-120 microns.
16. In a material fabrication environment for forming internal channels with curvilinear portions in a machined body, a method for smoothing a surface of the internal channels, comprising: attaching a grinding wheel at a distal end of a flexible shaft; engaging a drive source with a proximal end of the flexible shaft for rotation of the grinding wheel via the flexible shaft; inserting the grinding wheel into the channel; creating a fluid media in communication with the channel and the grinding wheel; and rotating the flexible shaft at a rotation speed for controlling an orbit of the grinding wheel against the surface of the channel.
17. The method of claim 16 further comprising: selecting an abrasive surface geometry on an outer surface of the grinding wheel; selecting a viscosity of a fluid flowing through the channel; and controlling the orbit of the grinding wheel based on the abrasive surface geometry and the selected viscosity.
18. The method of claim 17 further comprising generating a down-grinding orbit of the grinding wheel by engaging the grinding wheel against the surface of the channel in a direction the same as a rotation of the grinding wheel.
19. The method of claim 17 further comprising generating an up-grinding orbit of the grinding wheel by engaging the grinding wheel against the surface of the channel in a direction opposite to a rotation of the grinding wheel.
20. The method of claim 17, further comprising: selecting a rotation speed, fluid viscosity and grit size for controlling an orbital path of a grinding wheel; and operating the drive logic and a fluid supply for flowing the fluid based on the selected rotation speed, fluid viscosity and grit size.
21. A system for surface treatment of an interior surface of a conduit, comprising: a grinding wheel adapted for rotation; a flexible shaft attached to the grinding wheel and responsive to drive logic for rotation of the grinding wheel; a fluid supply for providing fluid to an interior of the conduit; and an abrasive surface geometry on an exterior of the grinding wheel, the drive logic for rotating the flexible shaft, the flexible shaft configured for a rotation speed for attaining an orbit of the grinding wheel based on a grit size of the abrasive surface geometry, a rotational speed of the grinding wheel and a viscosity of the fluid.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The foregoing and other features will be apparent from the following description of particular embodiments disclosed herein, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0008]
[0009]
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
DETAILED DESCRIPTION
[0016] Configurations disclosed below present a fixed abrasive, flexibly driven device capable of uniformly polishing surfaces of complex internal channels. Many precision industrial devices such as injection molds, turbine blades, and fuel nozzles include small, high aspect ratio cooling channels which must be polished to maximize cooling, fatigue life, and corrosion resistance.
[0017] Technology such as MAM enable the fabrication of complex internal channels with designs optimized for weight reduction, and thermal and fluid transfer efficiency. In one use case, conformal cooling channels for injection molds can increase productivity via reducing mold cooling time by up to 70%. Integrated fuel channels of jet engines increase fuel delivery efficiency by 15% while enhancing the heat transfer to the fuel through the optimized path of the channels. These complex channels with optimized designs, featuring small diameters, high aspect ratios, high tortuosity, and varied diameters and geometries, challenge the traditional casting and machining processes, and are amenable to one-piece constructions via MAM. As-built MAM parts often need post-processing for surface finishing. The average areal surface roughness (Sa) of as-built MAM parts ranges from 10 to 30 m with maximum peak to valley heights (Sz) of more than 150 m. High surface roughness negatively affects the fatigue life, corrosion resistance, and dimensional tolerance. For as-built MAM parts, the fatigue life can be reduced by 75% compared to conventional wrought or polished components; the corrosion resistance is diminished with surface protrusions as potential nucleation sites for metastable pitting, and the dimensional accuracy can be poor due to layer stratification, partially melted powders, and spatters, altering surface geometry. To address these challenges in as-built MAM parts, post-processing, including surface milling and grinding, laser machining, and shot peening, has been used to improve the surface finishing. Such post-processing techniques are mostly limited to exterior surfaces, due to line of sight and tooling restrictions, and not suitable for internal surface polishing.
[0018] Conventional internal surface polishing methods for MAM parts with complex channels include abrasive flow machining, hydrodynamic cavitation-assisted finishing, magnetic abrasive finishing, chemical polishing, and electrochemical polishing. Conventional approaches to interior surface polishing and grinding fail to utilize a hydrodynamic effect to control a driven device such as a polishing wheel. While some approaches employ a rotational driven impact, conventional approaches fail to embrace orbital control, particularly based on a grit size and rotational responses due to viscosity of a hydrodynamic fluid.
[0019] In another use case, internal cooling channels are essential to turbine blades for high efficiency power generation. The cooling channels lower the peak temperature experienced by the turbine blades, reduce thermal stresses within the blades, allow higher turbine entry temperature, and enhance efficiency and safety. These cooling channels, subjected to high-temperature, high-velocity air flow, need protective aluminide coating on the inner surface for corrosion and fatigue resistance. The aluminide coating of the cooling channels degrades due to oxidation. The accumulation of the aluminum oxide narrows the channels, limits the air flow and cooling, and leads to reduced efficiency and turbine blade failure. It is important to remove the aluminum oxide buildup and restore patency of the cooling channels to refurbish the turbine blades.
[0020] A uniform, adaptable method for quickly reducing surface roughness while maintaining dimensional integrity is significant to the adoption of MAM fabricated channels and similar structures. The disclosed approach satisfies this need by utilizing an adaptable drive system, a controllable high Material Removal Rate (MRR) grinding wheel, and a hydrodynamic effect which causes the grinding wheel to orbit the channel maintaining uniformity and dimensional integrity. A particular feature is the control of the grinding wheel orbit speed and direction through manipulation of the hydrodynamic effect. Orbit speed control directly correlates to the uniformity and consistency of the polishing process and can be altered to vary grinding mechanics to effect MRR and surface roughness. Orbit direction relative to the rotational direction fundamentally changes the grinding mechanics allowing for both up grinding and down grinding modes. Each method has specific process advantages which are detailed below. However, direct control of the orbit is not feasible due to the flexible nature of the drive system and indirect control through manipulation of system and process parameters. However, orbital control derives from controllable parameters and features of a shaft driven grinding wheel through rotation speed, grit size, fluid viscosity within the tube or vessel, and a shape of the grinding wheel, to name several.
[0021]
[0022] The device 100 of
[0023]
[0024] Configurations herein demonstrate control based on various parameters affecting the orbit, such as grinding wheel geometry, fluid medium, and grit size. Grinding wheel abrasive surface geometry could be altered in such a way as to increase the fluid flow to the contact area, increasing the hydrodynamic force. On this rationale, direct correlation of wheel design and orbital frequency can be obtained. Different grinding wheels with tailfins of different sizes may be employed for control of orbit direction based on geometry selection, disclosed further in
[0025]
[0026] The rotation may also induce an elastic force in the flexible shaft 112. The elastic force typically resulting from a nonlinear path of the conduit, as in
[0027] A third parameter involves selection of abrasive grit on the surface 122 of the grinding wheel 120, as one example of altering the grinding wheel abrasive surface among other parameters. Changing the grit size is preferable in many applications, with larger abrasive sizes increasing MRR and wheel life, while smaller sized produce better Sa. However, increase in grit size is accompanied by increase in cutting force which has been previously observed to affect orbit. Using this association, grit size may be modified or combined with different fluid media and wheel geometries to further control grinding wheel orbit. A relation of grit size 201 to orbit 203 is shown in
[0028]
[0029] Overall results for orbital control as in
[0030] As disclosed above, orbital control allows manipulation to favor an up-grinding or down-grinding orbital movement.
[0031] In operation, down-grinding creates a shorter, thicker chip (the name for the material removed by an individual abrasive grain), whereas up-grinding creates a longer, thinner chip. Due to chip geometry, down-grinding produces slightly higher material removal rates and grinding efficiency, with a rougher overall surface. Conversely, up-grinding generally produces a smoother surface, but with less efficiency.
[0032]
[0033]
[0034]
[0035] Therefore, the drive logic 150 is further configured to generate, based on the rotational speed, a hydrodynamic force 162 resulting from the viscosity and the grit size, such that the hydrodynamic force has components normal and outward to the interior surface, and tangential to the interior surface. The drive logic 150 may also manage the grinding force 160 having components inward and normal to the interior surface, and tangential to the interior surface and aligned with a rotation of the grinding wheel.
[0036]
[0037]
[0038] While the system and methods defined herein have been particularly shown and described with references to embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.