Electrochemical Machining (ECM) and its applications
分類：科學新知
2006/09/07 21:50
Electrochemical Machining (ECM) and its applications
分類：PEM 精密電化學加工技術
2006/09/07 08:06
碧威股份有限公司
www.tool-tool.com
轉述：
Electrochemical machining process can produce virtually any shaped cavity including through-holes and trepanned configurations. Furthermore, this process is unaffected by material hardness. BNI routinely manufacturers axial flow turbine blades and axisymmetric turbine nozzles in the following materials which are extremely difficult, and in some cases impossible, to machine by conventional methods.
ECM is essentially a deplating process that utilizes the principles of electrolysis. The ECM tool (cathode - pictured right) is positioned very close to the workpiece (anode) and a low voltage, high amperage DC current is passed between the two via an electrolyte. Material is removed from the workpiece and the flowing electrolyte solution washes the ions away. These ions form metal hydroxides which are removed from the electrolyte solution by centrifugal separation. Both the electrolyte and the metal sludge are then recycled.
Turbine Blading
The tight tolerance turbine blades (pictured left) were machined using ECM. BNI operates five ECM centers; three are designed for producing turbine blisks with a maximum diameter of 73.7 cm (29 inches). ECM provides a high-quality, efficient method for producing turbine wheels with intricate blades. Optimized leading edge shape and improved gas flow path consistency can be obtained due to superior control and repeatability. Additionally, Electrochemically Machined turbine blades can be placed closer together and as a result the turbine is more efficient.
Turbine Nozzles
The converging-diverging nozzles (pictured right) were electrochemically machined in Inconel® 625. Due to tight tolerances and extremely flat approach angles (usually 16º or less) ECM is often the most effective method for machining turbine nozzles blocks. Because no forces exist between the workpiece and tool, holes at virtually any angle can be machined into extremely hard materials. BNI's two electrochemical nozzle block machines have a maximum tool travel of 30.5 cm (12 inches) and a maximum total workpiece diameter of 76.2 cm (30 inches).
Complex Geometry Machining
Many difficult-to-machine, complex shapes can be produced accurately using ECM. This process also allows for the creation of internal helical splines in bores of various sizes and lengths for medical and process system applications. For example, this photo depicts a workpiece and the tool used to create it. On the left is the workpiece, a helical lobed air motor rotor used to power a thrust reverser for aircraft. On the right is the ECM tool used to remove material from the center of each of the 3 lobes in a helical pattern. Removing the material from the center of the lobes reduces the weight and inertia of the rotor. ECM is the only process that can perform this operation at a reasonable cost.
ECM Benefits
* No Recast Layer or IGA (Intergranular Attack)
* Excellent Surface Finish
* Superior Tolerance, Control, and Repeatability
* Unaffected by Material Hardness
* Able To Produce Complex Shapes
* Extremely Fast (One-Pass Machining)
* Superior Stress-Free Surface
* Absence of Burrs
*
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