US3352774A - Apparatus for electrolytically tapered or contoured cavities - Google Patents

Apparatus for electrolytically tapered or contoured cavities Download PDF

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Publication number
US3352774A
US3352774A US534931A US53493166A US3352774A US 3352774 A US3352774 A US 3352774A US 534931 A US534931 A US 534931A US 53493166 A US53493166 A US 53493166A US 3352774 A US3352774 A US 3352774A
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United States
Prior art keywords
electrode
workpiece
electrolyte
cavity
tip
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Expired - Lifetime
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US534931A
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English (en)
Inventor
Lynn A Williams
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Anocut Engineering Co
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Anocut Engineering Co
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Filing date
Publication date
Priority to NL274928D priority Critical patent/NL274928A/xx
Priority claimed from US90438A external-priority patent/US3257300A/en
Priority to CH199062A priority patent/CH389123A/fr
Priority to GB6629/62A priority patent/GB1002957A/en
Priority to FR888623A priority patent/FR1316113A/fr
Application filed by Anocut Engineering Co filed Critical Anocut Engineering Co
Priority to US534931A priority patent/US3352774A/en
Application granted granted Critical
Publication of US3352774A publication Critical patent/US3352774A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
    • B23H3/04—Electrodes specially adapted therefor or their manufacture

Definitions

  • This invention relates to electrodes for electrolytic shaping.
  • a principal object of this invention is to provide equipment for the formation of cavities having tapered or contoured side walls with a smooth and in some instances with a high finish.
  • Another object is to provide electrodes usable in electrolytic cavity sinking to carry out the objective of the immediately preceding paragraph.
  • Another object is to facilitate the manufacture of suitable tool electrodes for forming such cavities.
  • FIG. 1 is a schematic view in elevation of the work area of apparatus used in the practice of this invention
  • FIG. 2 is a frontal view showing the working tip of a wedge electrode of this invention
  • FIG. 3 is a side elevation of the electrode of FIG. 2;
  • FIG. 4 is an end view of the electrode of FIG. 2;
  • FIG. 5 is a sectional view of a workpiece showing a preliminary roughing cut
  • FIG. 6 is a similar view of the same workpiece shown in FIG. 5 after finishing the cut to produce tapered side walls;
  • FIG. 7 is a side elevation of an electrode for forming a slot as a first step in the practice of the invention.
  • FIG. 8 is an end view of the electrode of FIG. 7;
  • FIG. 9 is a side elevation of a finishing electrode
  • FIG. 10 is an end view of the finishing electrode of FIG. 9;
  • FIG. 11 is a sectional view of a workpiece with a roughing slot formed by the electrode of FIGS. 7 and 8;
  • FIG. 12 is a sectional view of the same workpiece after it has been contoured by the electrode of FIGS. 9 and 10;
  • FIG. 13 is a view, partly in section, of a modified arrangement wherein a solid contouring electrode is used with the electrolyte being introduced through a hole in the workpiece.
  • the electrode is arranged in such a way as to cause always a kind of outwardly wedging action against the work material, thereby tending constantly to confine the electrolyte, to maintain its pressure, and to maintain high velocity, then it is possible to secure close conformation of shape between the cavity in the workpiece and that on the electrode. And, at the same time, it is possible to produce a bright, specular finish even though the electrolyte solutions used are not of the kind ordinarily regarded as having electro polishing characteristics.
  • FIG. 1 shows schematically the general configuration of the apparatus.
  • An electrode E is mounted to a manifold M, which is fed with a hose H with electrolyte under a pressure of to 300 p.s.i. at the manifold and at the entrance to the electrode.
  • the manifold M is mounted in turn to a holder H1 which is fastened to a front plate of a ram R.
  • the front plate is electrically insulated from the body of the ram, and the ram itself is protected against electrolyte by a collapsible boot B.
  • Direct current of a voltage not appreciably greater than about 18 volts is supplied from a source of the type disclosed in the copending application of Lynn A. Williams, Ser. No.
  • the ram is arranged to be advanced under a positive drive at a predetermined fixed rate in the direction of the arrow toward the work, thereby moving the electrode linearly into the workpiece.
  • a more detailed description of the type of apparatus which may be used is shown in the copending application of Lynn'A. Williams, entitled Electrolytic Cavity Sinking Apparatus and Method, Ser. No. 73,154, filed Sept. 2, 1960, and now issued into Patent No. 3,275,543, dated Sept. 27, 1966.
  • FIG. 2 shows one form of electrode used in the practice of the invention. It consists of an electrode proper 21, which is made of copper and is mounted in the manifold member M, which, in turn, may be either fastened to or made integrally with a holder plate H1.
  • the manifold M is recessed as shown at 23, and provision is made for connection of a hose through a screw-threaded opening 25.
  • the electrode 21 conforms to the shape of the recess 23 in the manifold, and may be fastened into it by any suitable means, for example, by brazing or soldering.
  • the electrode proper 21 is arranged to feed electrolyte from the recess 23 of the manifold to. its working tip by a plurality of feed holes or passages 27. These should be drilled as conveniently close together as is possible without breaking out from one hole through the land into the next. In an electrode having a working tip with a width of the order of A, the holes should be about A" in diameter, and, in general, the more open and free the passage for electrolyte the better.
  • the holes 27 are not carried through all the, way to the working tip of the electrode but terminate about A" to 1" above it, where they are intersected by a transverse slot 29 which is milled into the end of the electrode in such a way as to communicate with the holes 27.
  • the slot may be about ,4 wide for an electrode of this size.
  • the slot 29 should be deep enough so as to smooth out the flow from the several holes 27, so that the electrolyte issues, smoothly through the slot with a minimum reflection of the pattern of holes through which it previously passed.
  • This electrode is not insulated either on its sides or on its ends, but is left bare for the purpose of producing tapered side walls 30.
  • the electrode may be used in either of two ways. Either it may be simply advanced into a raw piece of work, using the maximum penetration rate which is obtainable, or, preferably, it may be used to enlarge a cavity previously made by a slotting electrode; for example, one like that shown in FIGS. 7 and 8 or as shown in one or more of the previously identified applications.
  • a cut of this preliminary kind is shown in FIG. 5. There is no basic reason why it could notbe produced by conventional machining as well as by electrolytic means, although ordinarily formation of cavities of this sort can be accomplished more quickly by use of electrolytic machining techniques than by conventional methods.
  • the width and length of the preliminary cut as shown in FIG. should be about the size of the working tip of the tapered electrode shown in FIGS. 2, 3 and 4.
  • the method of advancing. the tapered electrode directly into a workpiece without making a preliminary cut can be carried out where the taper on the sides and ends of the electrode'is'sulficiently great (say, 30 from the line of advance of the electrode). As the angle of taper becomes less, a point is reached where it is necessary to make a preliminary cut like that shown in the workpiece of FIG. 5.
  • FIG. 6 shows the shape of the tapered cavity formed in the same workpiece shown in FIG. 5 by using the electrode of FIGS. 2, 3 and 4.
  • the supply hose H should be large enough to deliver the full volume without substantial loss of pressure, and, similarly, the manifold recess 23 should be adequate in size to assure full flow and uniform distribution.
  • FIGS. 7, 8, 9 and '10 a somewhat different application of the same invention is shown.
  • FIGS. 7 and 8 show a simple electrodefor making a rectangular cavity.
  • the electrode proper 21 may be made like other electrodes 1 of copper. It is fitted into a recess 23 in a manifold M which, in turn, is fastened to a holder ormounting plate H1. The cavity 23 is fed by an opening adapted to receive a hose connection as at 25.
  • the electrode proper is drilled with feed holes or passages 27, which are closely spaced as previously described in connection with the electrode of FIGS. 2, 3 and 4.
  • Aislot 29 is milled into the electrode near its tip, and then, an additional member serving as a flange plate 31. is fastened to the body of the electrode by brazing or soldering. This additional flange plate is arranged to project beyond the body of the electrode by about .010 to .030 with the purpose of providing clearance for insulating material 33, which is applied to the body of the electrode to prevent excessive side action.
  • FIGS. 9 and 10 is used in order to modify the shape of the cavity to provide radii on all of the side walls.
  • This electrode of FIGS. 9 and 10 is made in substantially the same way as the electrodes previously described herein with like reference indicia referring to similar parts.
  • this type is machined to a shape to provide a fullradius as shown at R.
  • This may be any contour which is desired and may be either straight or'curved as the Work requirements dictate.
  • the electrode of FIGS. 9 and 10 is positioned so that the working tip of this electrode registers with the previously formed cavity. his not critical that the working face should have identically the same contour as the cavity, but the deviation should not be excessive and, particularly important, there should not be any place where the cavity is so much larger than the finishing electrode that any large amount of the electrolyte will escape through the gap which would thus be formed. Except for this, however, close conformity is desirable but not necessary.
  • an electrode like that of FIGS. 7 and 8 has been made as a roughing electrode, its dimensions being 2" in length and Vs" in width.
  • the cavity like that shown in FIG. 11 was produced with an infeed rate of advance of .100" per minute using a direct current of 14 volts and an electrode pressure of about 200 p.s.i.
  • the cavity in the workpiece was carried to a depth of .200".
  • an electrode like that of FIGS. 9 and 10 was applied, using a feed rate of .200" per minute, an electrolyzing current at a voltage of 13 volts and a total penetration to a depth of .187".
  • Another electrolyte can be made of four pounds of salts to each gallon of water, the salts being in the following ratio:
  • FIG. 13 there is illustrated an arrangement for forming a tapered or contoured cavity without using a hollow electrode.
  • the workpiece WK is initially formed with a through cavity 35 by electrolytic or conventional machining techniques.
  • the workpiece is mounted or clamped in a fixture or bracket 37 having one or more passages 39 therethrough adapted to be placed in communication with the workpiece cavity 35. If the workpiece cavity is large or elongate then two, three or more fixture passages 39 fed from a manifold similar in function to the manifold M of FIGS. 2 to 4, 9 and 10, should be provided.
  • the passage or passages 39 (or manifold if one is used) is connected to the previously mentioned electrolyte supply source by the hose H and fitting 41 so that a copious supply of electrolyte under pressure may be obtained.
  • the electrode 43 is similar in configuration (for illustration purposes only) to that shown in FIGS. 9 and 10 but is made of a solid block of copper or other suitable material and is mounted directly upon the holder H1 to be connected into the electrolyzing power circuit in a manner to be cathodic. It is formed with contouring radii R which are adapted electrolytically to form contoured surfaces R" on the workpiece WK.
  • the electrode 43 With the electric current turned on and electrolyte being supplied to the rough workpiece cavity 35, the electrode 43 is advanced into the work with a positive feed and at a constant rate.
  • the rough cavity in the workpiece forms a plenum ahead of the advancing electrode and as the electrolyte escapes from the cavity between the electrode surfaces R and the workpiece the latter is electrolytically eroded to the shape of the surfaces R" to have a smooth finish and, depending upon the character of the workpiece material, perhaps a high specular finish.
  • FIGS. 2, 3 and 4 having a rather regular shape
  • other electrodes have also been used in which, while the same general tapered configuration was employed, the actual shape was the rather complex shape existing between two blades of a turbine wheel, the blades themselves having a twist or camber and, at the same time, a constantly changing section.
  • a preliminary, straight-sided cut was made into a disc of material at a point roughly representing the midpoint between two of the blades.
  • the wedge shaped electrode formed to produce the interblade cavity was introduced at a high rate of feed in order to shape and finish the convex side of one blade and, concurrently, the joining concave side of the next blade.
  • the electrode should be one in which its section grows larger as it is advanced into the work so as to remove material by side action while at all times forcing the electrode into the cavity to maintain close spacing between the electrode and the Work, a spacing of the order of 0.15" or less while, at the same time, maintaining electrolyte pressure of the order of p.s.i. or more and, at the same time, maintaining high velocity of electrolyte flow.
  • the rate of advance necessary to bring about these conditions will, of course, be determined by the taper. If the taper is shallow, then the electrode may have to be advanced very rapidly, as rapidly, for example, as an inch per minute or even more. On the other hand, if the taper is steeper then a slower rate of advance will maintain the desired condition.
  • an electrolytic machining apparatus for forming tapered or contoured cavities in an electrically conductive and electrochemically erodible workpiece, the apparatus having means for supporting the workpiece and an electrode for movement relatively toward each other, means for pumping an electrolyte between the workpiece and the electrode, and means connected for passing an electrolyzing current between the workpiece and the electrode, the electrode comprising an electrode body made of a conductive material having at one end thereof a working tip, electrolyte passages extending through said body from the opposite end thereof to said tip, a transverse slot in said tip interconnecting said passages, the external surface of said body flaring outwardly away from said tip to be shaped complementally to the contour of the cavity to be formed, means for forming a plenum chamber secured to said body at said opposite end and in communication with said passages, and an inlet connection to said plenum chamber.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Mechanical Engineering (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
US534931A 1961-02-20 1966-01-17 Apparatus for electrolytically tapered or contoured cavities Expired - Lifetime US3352774A (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
NL274928D NL274928A (fr) 1961-02-20
CH199062A CH389123A (fr) 1961-02-20 1962-02-19 Procédé pour l'usinage électrochimique d'une cavité à parois évasées
GB6629/62A GB1002957A (en) 1961-02-20 1962-02-20 Improvements in or relating to electrolytic machining
FR888623A FR1316113A (fr) 1961-02-20 1962-02-20 Procédé pour l'usinage d'une cavité de section décroissante ou profilée
US534931A US3352774A (en) 1961-02-20 1966-01-17 Apparatus for electrolytically tapered or contoured cavities

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US90438A US3257300A (en) 1961-02-20 1961-02-20 Method for electrolytically forming tapered or contoured cavities
US534931A US3352774A (en) 1961-02-20 1966-01-17 Apparatus for electrolytically tapered or contoured cavities

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US3352774A true US3352774A (en) 1967-11-14

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US534931A Expired - Lifetime US3352774A (en) 1961-02-20 1966-01-17 Apparatus for electrolytically tapered or contoured cavities

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US (1) US3352774A (fr)
CH (1) CH389123A (fr)
GB (1) GB1002957A (fr)
NL (1) NL274928A (fr)

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US20140001035A1 (en) * 2012-06-29 2014-01-02 GM Global Technology Operations LLC Electrolytic cell, method for enhancing electrolytic cell performance, and hydrogen fueling system
US10422250B2 (en) 2012-09-27 2019-09-24 Malta Inc. Pumped thermal systems with variable stator pressure ratio control
US10436109B2 (en) 2016-12-31 2019-10-08 Malta Inc. Modular thermal storage
US10458284B2 (en) 2016-12-28 2019-10-29 Malta Inc. Variable pressure inventory control of closed cycle system with a high pressure tank and an intermediate pressure tank
US10801404B2 (en) 2016-12-30 2020-10-13 Malta Inc. Variable pressure turbine
US10907510B2 (en) 2016-12-28 2021-02-02 Malta Inc. Storage of excess heat in cold side of heat engine
US10907548B2 (en) 2016-12-29 2021-02-02 Malta Inc. Use of external air for closed cycle inventory control
US10907513B2 (en) 2010-03-04 2021-02-02 Malta Inc. Adiabatic salt energy storage
US10920667B2 (en) 2016-12-28 2021-02-16 Malta Inc. Pump control of closed cycle power generation system
US11053847B2 (en) 2016-12-28 2021-07-06 Malta Inc. Baffled thermoclines in thermodynamic cycle systems
US11286804B2 (en) 2020-08-12 2022-03-29 Malta Inc. Pumped heat energy storage system with charge cycle thermal integration
US11396826B2 (en) 2020-08-12 2022-07-26 Malta Inc. Pumped heat energy storage system with electric heating integration
US11454167B1 (en) 2020-08-12 2022-09-27 Malta Inc. Pumped heat energy storage system with hot-side thermal integration
US11480067B2 (en) 2020-08-12 2022-10-25 Malta Inc. Pumped heat energy storage system with generation cycle thermal integration
US11486305B2 (en) 2020-08-12 2022-11-01 Malta Inc. Pumped heat energy storage system with load following
US11678615B2 (en) 2018-01-11 2023-06-20 Lancium Llc Method and system for dynamic power delivery to a flexible growcenter using unutilized energy sources
US11852043B2 (en) 2019-11-16 2023-12-26 Malta Inc. Pumped heat electric storage system with recirculation
US11982228B2 (en) 2020-08-12 2024-05-14 Malta Inc. Pumped heat energy storage system with steam cycle

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US4083946A (en) * 1977-03-23 1978-04-11 E. I. Du Pont De Nemours And Company Process for removing chloride impurities from TiO2

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GB141489A (en) * 1919-03-27 1920-04-22 Walter Edward Bodycoat Improvements in anti-splash devices for water taps
US1787247A (en) * 1929-11-30 1930-12-30 Air Reduction Method of shaping edges for fusion welding
DE583609C (de) * 1932-04-16 1933-09-06 Benkiser Werk Akt Ges Auslaufhahn fuer Fluessigkeiten mit in der Auslaufhuelse angeordneten, mit einem selbsttaetigen Rueckschlussventil verbundenen Ventilkoerper
US2059236A (en) * 1932-08-13 1936-11-03 Electric Arc Cutting & Welding Method of machining by electric current
US2101214A (en) * 1937-02-15 1937-12-07 New York Air Brake Co Wasp excluder for air brakes
US2650979A (en) * 1950-06-21 1953-09-01 Method X Company Method and apparatus for electrically disintegrating metallic material
US2750332A (en) * 1952-06-04 1956-06-12 Pittsburgh Plate Glass Co Method and apparatus for electrodeposition of a layer of uniform thickness on a conductive surface
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US2909641A (en) * 1958-05-02 1959-10-20 Republic Aviat Corp Tool for electro-shaping
US3051638A (en) * 1959-03-12 1962-08-28 United States Steel Corp Method and apparatus for making a tapered thread
US3095364A (en) * 1959-11-27 1963-06-25 Steel Improvement & Forge Comp Material removal
US3144541A (en) * 1961-07-13 1964-08-11 Gen Motors Corp Electrical stock removal apparatus

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB141489A (en) * 1919-03-27 1920-04-22 Walter Edward Bodycoat Improvements in anti-splash devices for water taps
US1787247A (en) * 1929-11-30 1930-12-30 Air Reduction Method of shaping edges for fusion welding
DE583609C (de) * 1932-04-16 1933-09-06 Benkiser Werk Akt Ges Auslaufhahn fuer Fluessigkeiten mit in der Auslaufhuelse angeordneten, mit einem selbsttaetigen Rueckschlussventil verbundenen Ventilkoerper
US2059236A (en) * 1932-08-13 1936-11-03 Electric Arc Cutting & Welding Method of machining by electric current
US2101214A (en) * 1937-02-15 1937-12-07 New York Air Brake Co Wasp excluder for air brakes
US2650979A (en) * 1950-06-21 1953-09-01 Method X Company Method and apparatus for electrically disintegrating metallic material
US2750332A (en) * 1952-06-04 1956-06-12 Pittsburgh Plate Glass Co Method and apparatus for electrodeposition of a layer of uniform thickness on a conductive surface
DE964556C (de) * 1953-12-18 1957-05-23 Knapsack Ag Vorrichtung zum Anschneiden von brennschneidbaren Werkstuecken
US2909641A (en) * 1958-05-02 1959-10-20 Republic Aviat Corp Tool for electro-shaping
US3051638A (en) * 1959-03-12 1962-08-28 United States Steel Corp Method and apparatus for making a tapered thread
US3095364A (en) * 1959-11-27 1963-06-25 Steel Improvement & Forge Comp Material removal
US3144541A (en) * 1961-07-13 1964-08-11 Gen Motors Corp Electrical stock removal apparatus

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US20140001035A1 (en) * 2012-06-29 2014-01-02 GM Global Technology Operations LLC Electrolytic cell, method for enhancing electrolytic cell performance, and hydrogen fueling system
US9487872B2 (en) * 2012-06-29 2016-11-08 GM Global Technology Operations LLC Electrolytic cell, method for enhancing electrolytic cell performance, and hydrogen fueling system
US11156385B2 (en) 2012-09-27 2021-10-26 Malta Inc. Pumped thermal storage cycles with working fluid management
US11754319B2 (en) 2012-09-27 2023-09-12 Malta Inc. Pumped thermal storage cycles with turbomachine speed control
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US10422250B2 (en) 2012-09-27 2019-09-24 Malta Inc. Pumped thermal systems with variable stator pressure ratio control
US10458721B2 (en) 2012-09-27 2019-10-29 Malta Inc. Pumped thermal storage cycles with recuperation
US10428694B2 (en) 2012-09-27 2019-10-01 Malta Inc. Pumped thermal and energy storage system units with pumped thermal system and energy storage system subunits
US10428693B2 (en) 2012-09-27 2019-10-01 Malta Inc. Pumped thermal systems with dedicated compressor/turbine pairs
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US10920674B2 (en) 2016-12-28 2021-02-16 Malta Inc. Variable pressure inventory control of closed cycle system with a high pressure tank and an intermediate pressure tank
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US11053847B2 (en) 2016-12-28 2021-07-06 Malta Inc. Baffled thermoclines in thermodynamic cycle systems
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US11852043B2 (en) 2019-11-16 2023-12-26 Malta Inc. Pumped heat electric storage system with recirculation
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Publication number Publication date
CH389123A (fr) 1965-03-15
GB1002957A (en) 1965-09-02
NL274928A (fr)

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