US3409534A - Electrolytic material removal apparatus - Google Patents

Electrolytic material removal apparatus Download PDF

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Publication number
US3409534A
US3409534A US517239A US51723965A US3409534A US 3409534 A US3409534 A US 3409534A US 517239 A US517239 A US 517239A US 51723965 A US51723965 A US 51723965A US 3409534 A US3409534 A US 3409534A
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US
United States
Prior art keywords
electrolyte
nozzle
workpiece
cathode
conduit
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US517239A
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English (en)
Inventor
James D Andrews
Carl E Shurts
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Electric Co
Original Assignee
General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by General Electric Co filed Critical General Electric Co
Priority to US517239A priority Critical patent/US3409534A/en
Priority to GB30482/66A priority patent/GB1159115A/en
Priority to NL6610484A priority patent/NL6610484A/xx
Priority to DE19661565555 priority patent/DE1565555B1/de
Priority to CH1365866A priority patent/CH456798A/de
Priority to SE13061/66A priority patent/SE335940B/xx
Priority to FR78176A priority patent/FR1497707A/fr
Priority to BE712507D priority patent/BE712507A/xx
Application granted granted Critical
Publication of US3409534A publication Critical patent/US3409534A/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
    • B23H9/00—Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
    • B23H9/14—Making holes
    • B23H9/16—Making holes using an electrolytic jet

Definitions

  • This invention relates to the electrolytic removal of material from an electrically conductive workpiece and, more particularly, to apparatus for use in the production of multiple small holes or cavities in a workpiece by such a method.
  • the method for removing material electrolytically from an electrically conductive workpiece in cludes placing a cathode-tool and an anode-workpiece one opposite the other while at the same time passing an electric current between the cathode and anode through an electrolyte.
  • the shape and size of the cathode depends upon the shape and size of that portion of the workpiece which is to be removed and the cavity or hole to be produced.
  • This process and its associated apparatus and tooling has been described in detail in the public literature and in the patented art.
  • the known literature is directed principally to the use of relatively large cathodes the shape of which is closely related to the shape to be produced in the workpiece. Such cathodes are positioned across a relatively narrow gap from the workpiece.
  • This method which is sometimes referred to as electrolytic machining, electrolytic cutting, electrolytic drilling, and the like, has been described to include passing current at relatively low voltages between the cathode and the anodeworkpiece.
  • the diameter of holes which could be produced electrolytically in an electrically conductive workpiece was limited by the size of a cathode tube through which electrolyte could pass and which could penetrate the workpiece.
  • a practical limitation on the tube outside diameter for production use was no less than about 0.050.
  • a single electrolyte nozzle could be readily located opposite a workpiece. Then either the workpiece or the nozzle could be fed one toward the other or could be traversed relatively one to the other to produce a desired shape or cavity.
  • the co-ordinated movement of the plurality of electrolyte di recting nozzles and workpiece presented operational difficulties. This was a particular problem in those situations in which it was desired that the multiple separate cathodes, and hence the electrolyte nozzles, be fed toward the workpiece.
  • Such an embodiment required movement of the means to carry electrolyte to each of the electrolyte directing nozzles from a single source of electrolyte as well as movement of the means to charge each of the electrolyte streams from a single source of electrical power.
  • a principal object of the present invention is to provide improved apparatus for use in the electrolytic removal of material from an electrically conductive workpiece through a plurality of charged electrolyte streams each at least at the threshold of glow discharge and each directed from nozzles readily movable with respect to the workpiece.
  • Another object is to provide such apparatus which allows easy replacement of nozzles such as for change in hole size or because of nozzle damage.
  • a further object is to provide improved apparatus for use in such an electrolytic material removal process in which the cathode is particularly located with respect to the workpiece to provide process control as well as accurate and repeatable hole production.
  • FIG. 1 is a partially sectional, partially diagrammatic view of one form of the apparatus of the present invention.
  • FIG. 2 is a partially sectional view of another form of the electrolyte manifold in the apparatus of the present invention.
  • the electrolyte and an electric conducting means are brought together in an electrolyte chamber of a manifold.
  • Those surfaces of the manifold which are'in contact with the electrolyte are a dielectric material.
  • the manifold is made of a dielectric material.
  • the manifold includes means to introduce the electrolyte into the electrolyte chamber.
  • the electrical conducting means in the electrolyte chamber is electrically connected with an electric power source. Communicating with the manifold are a plurality of hollow flexible electrolyte conduits of a dielectric material, such as a plastic.
  • Each conduit such as a tube, communicates with the electrolyte chamber to allow the electrolyte to pass from the chamber into the conduit.
  • a flexible cathode which is electrically connected with the electric conducting means passes through each conduit and terminates in a cathode tip beyond that end of the conduit remote from the manifold.
  • the apparatus further includes a plurality of hollow electrolyte directing nozzles of a dielectric material comprising a body, a capillary end open at the nozzle tip and a transition section joining thebody with the capillary end. The transition section decreases in diameter from the body toward the capillary end.
  • each conduit remote from the manifold, with its respective electrolyte directing nozzle to allow the electrolyte to flow through each nozzle and toward a workpiece from teh nozzle tip.
  • the cathode tip is located within the body of the nozzle. It has been found that the cathode tip must be located at a point about %%t" from the location at which the transition section joins the body of the nozzle.
  • the apparatus further includes nozzle holding and locating means releasably connected with the body of each nozzle to hold and position the nozzles with respect to the workpiece.
  • Manifold in this embodiment is made of a dielectric material such as a polymerized methyl methacrylate resin some forms of which are known as Lucite plastic and Plexiglas plastic.
  • a dielectric material such as a polymerized methyl methacrylate resin some forms of which are known as Lucite plastic and Plexiglas plastic.
  • An electrical conducting means 20, such as a wire or rod, is connected electrically through a wall such as at 22 of the manifold to a source of electrical power not shown but represented by the negative charge 24.
  • the walls of the manifold 10 in contact with the electrolyte in chamber 12 are covered with a dielectric material in the event the entire body of the manifold 10 is not itself of a dielectric material.
  • each of a plurality of hollow flexible electrolyte conduits 26, such as of plastic tubing, is connected to manifold 10 so that each communicates with the electrolyte chamber 12 to allow electrolyte to pass from the chamber into each conduit.
  • Conduits 26, electrolyte supply means such as tube 28, and electrical conductor 20 through wall 22 can be secured to the manifold by a clamping and sealing means 30, for example, of a type shown in more detail in FIG. 2.
  • Each cathode In electrical connection with electric conductor 20 are a plurality of flexible cathodes such as wires 32 each extending through an electrolyte conduit 26 and extending past end 34 of each conduit 32, remote from manifold 10. Each cathode terminates in cathode tip 36.
  • Each hollow electrolyte directing nozzle one of which is shown generally at 40, includes a body 42 and a capillary end 44 open at tip 46 which is directed toward workpiece 48. Between capillary end 44 and body 42 is a transition section 50 joining the body 42 with the capillary end 44 and decreasing in cross-sectional diameter from the body toward the capillary end.
  • the location 52 at which the transition section joins the body of the nozzle is that at which the transition section starts to decrease in cross-sectional diameter with respect to the cross-sectional diameter of the body.
  • cathode tip 36 must be located within a distance, shown as D in the drawing, of about A" to from location 52 at which the transition section joins the body of the nozzle. If tip 36 is closer to location 52 than about A", the flow of electrolyte through capillary end 44 is reduced to a point which causes loss of control of hole size produced in workpiece 48, the production generally larger than desired holes and significantly reduced life of nozzle tip 46. If cathode tip 36 is farther than about A from location 52 gases in the electrolyte form into bubbles which results in loss of process control and erratic hole size. This distance is particularly significant with the use of capillary ends having an inside diameter of about 0.03 or less.
  • each nozzle 40 is releasably secured by clamping means such as 54 to its respective conduit 26 to allow the electrolyte to pass from the conduit into the nozzle and subsequently to workpiece 48.
  • the body of each nozzle 40 is releasably secured with a nozzle holding and locating means such as metal plate 56 through which holes such as 58 have been produced to receive the body of nozzle 40.
  • the holes 58 are large enough to allow nozzle 40 to be removed for replacement by release or removal of the clamping means securing the nozzle with the conduit 26 and with means 56.
  • a locator 60 and a lock means 62 are attached with body 40.
  • clamp means 54 and locators and locks 60 and 62, respectively can be removed and the nozzle can be replaced without disturbing the means connected with manifold 10 to supply electrolyte to each conduit 26 and without disturbing the electrical connection between the power source 24, electric conductor 20 and the plurality of cathodes 32.
  • FIG. 1 a plurality of cathode wires 32 are connected with electrical conductor 20 at a plurality of points 62.
  • points 62 can be a common point as well as separate points on conductor 20.
  • FIG. 2 shows a manifold on which point 62 is a common one for each of the cathodes 32.
  • the nozzle holding and locating means 56 of FIG. 1 can be movable such as with standard and well known machines, represented diagrammatically by arrows 64, in a variety of directions with respect to workpiece 48.
  • the advantage of providing means 56 and hence nozzles 40 to be movable in a variety of directions with respect to the workpiece while at the same time maintaining manifold 10 in a fixed position has particular significance in the production of the plurality of holes or cavities in workpiece 48.
  • problems relating to the loosening of connectors, wear and breakdown of insulation and contacts, and the like with regard to manifold 10 are thus eliminated.
  • easy replacement of nozzles 40 are provided.
  • the manifold is shown in an embodiment generally at 10a in which a plurality of channels 70, functionally equivalent to openings 72 in the manifold 10 of FIG. 1, are directed to a common point.
  • Cathodes 32 are joined with electrical conductor 20 at 62. Electrolyte from conduit 28 is directed to that point for passage subsequently through each channel 70 to flexible conduit 26 as described above.
  • Example 1 A nozzle having a capillary end of 0.014 outside diameter and 0.0125" inside diameter was used in an electrolyic process to produce holes in a tube of a nickel base alloy having a nominal composition, by weight, of 0.1% (max.) C; 15% Cr; 3% Cb; 3% Mo; 3% W; 7% Fe; 0.5% A1; 0.6% Ti; 0.006 B; with the balance Ni and incidental impurities, and sometimes referred to as IN 102 nickel base alloy.
  • the tube had an outside diameter of about 0.2" and a wall thickness of about 0.04". The aim was to produce 0.017" diameter holes.
  • the electrolyte used was an aqueous solution of 10% H 50 applied at a pressure of about 40-60 p.s.i.
  • the power applied was at a potential of 500 volts at 300 milliamps.
  • the tip 36 of cathode 32 was placed within the range of A" to A" from the location 52 at which the transition section of the nozzle joins the nozzle body. Holes of 0.017" were consistently produced and nozzle tip 46 was essentially unaffected for as many as about 10,000 holes.
  • Example 2 The conditions, materials and apparatus of Example 1 were used in this example except that tip 36 of cathode 32 was placed at a distance less than A" from location 52. Holes of about 0.020" diameter were produced rather than 0.017" and the life of nozzle tip 46 was limited to about 100 holes before replacement was required.
  • Example 3 The conditions, materials and apparatus of Example 1 were used in this example except that tip 36 of cathode 32 was placed at a distance greater than A from location 52. Holes of erratic size fluctuating between 0.015 and 0.017" were produced along with formation of gas bubbles which aflected process control.
  • Improved apparatus for use in the electrolytic removal of material from an electrically conductive workpiece comprising:
  • a manifold having walls enclosing an electrolyte chamher, the surfaces of the manifold in contact with the electrolyte being dielectric;
  • a hollow flexible electrolyte conduit of a dielectric material communicating with the electrolyte chamber to allow electrolyte to pass from the chamber into the conduit;
  • a flexible cathode electrically connected with the electric conducting means, the cathode passing through the conduit and terminating in a cathode tip beyond an end of the conduit remote from the manifold;
  • a hollow electrolyte directing nozzle of a dielectric material comprising a body, a capillary end open at the nozzle tip and a transition section joining the body with the capillary end, the transition section decreasing in diameter from a location on the body toward the capillary end, the nozzle tip directed at the electrically conductive workpiece;
  • the cathode tip being located 'Within the body of the nozzle about A"% from the location at which the transition section joins the body of the nozzle;
  • nozzle holding and locating means releasably connected with the body of the nozzle to hold and to position the nozzle with respect to the workpiece.
  • the improved apparatus of claim 1 for use in the electrolytic removal of material from an electrically conductive workpiece comprising:
  • a manifold of a dielectric material having walls enclosing an electrolyte chamber
  • a plurality of hollow flexible electrolyte conduits each of a dielectric material and each communicating with the electrolyte chamber to allow electrolyte to pass from the chamber into each conduit;
  • each cathode for each conduit electrically connected with the electric conducting means, each cathode passing from the electrolyte chamber through the conduit and terminating in a cathode tip beyond an end of the conduit remote from the manifold;
  • a hollow electrolyte directing nozzle for each cathode of a dielectric material comprising a body, a capillary end open at the nozzle tip and a transition section joining the body with the capillary end, the capillary end having an inside diameter of no greater than about 0.03", the transition section decreasing in diameter from a location on the body toward the capilllary end, the open nozzle tip directed toward the electrically conductive workpiece;
  • releasable means connecting each conduit with its associated nozzle to allow electrolyte to flow from the conduit through the nozzle and toward the workpiece from the nozzle tip;
  • the cathode tip being located within the body of the nozzle about A-%" from the location at which the transition section joins the body of the nozzle;
  • movable nozzle holding and locating means releasably connected with the body of the nozzle to hold and to position the nozzle with respect to the workpiece.
  • each electric conducting means in each electrolyte chamber passing through a wall of each manifold, each electric conducting means electrically connected with the electric power source;
  • each conduit a plurality of hollow flexible electrolyte conduits each of a dielectric material, each communicating with its respective electrolyte chamber to allow electrolyte to pass from the chamber into each conduit;
  • each conduit electrically connected with the electric conducting means in its respective electrolyte chamber, each cathode passing from its electrolyte chamber through the conduit and terminating in a cathode tip beyond an end of the conduit remote from the manifold;
  • a hollow electrolyte directing nozzle for each cathode of a dielectric material comprising a body, a capillary end open at the nozzle tip and a transition section joining the body with the capillary end, the capillary end having an inside diameter of no greater than about 0.03", the transition section decreasing in diameter from the body toward the capillary end, the open nozzle tip directed toward the electrically conductive workpiece;
  • releasable means connecting each conduit with its associated nozzle to allow electrolyte to flow from the conduit through the nozzle and toward the workpiece from the nozzle tip;
  • the cathode tip being located within the body of the nozzle about MH A" from the location at which the transition section joins the body of the nozzle;
  • movable nozzle holding and locating means releasably connected with the body of the nozzle to hold and to position the nozzle with respect to the workpiece.

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  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
US517239A 1965-12-29 1965-12-29 Electrolytic material removal apparatus Expired - Lifetime US3409534A (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US517239A US3409534A (en) 1965-12-29 1965-12-29 Electrolytic material removal apparatus
GB30482/66A GB1159115A (en) 1965-12-29 1966-07-07 Improvements in Electrolytic Material Removal Apparatus
NL6610484A NL6610484A (en)) 1965-12-29 1966-07-26
DE19661565555 DE1565555B1 (de) 1965-12-29 1966-08-04 Vorrichtung zur elektrolytischen Herstellung von L¦chern in Werkstücken
CH1365866A CH456798A (de) 1965-12-29 1966-09-22 Vorrichtung zum elektrolytischen Abtragen von Material
SE13061/66A SE335940B (en)) 1965-12-29 1966-09-28
FR78176A FR1497707A (fr) 1965-12-29 1966-09-29 Appareil pour l'enlèvement de matière par électrolyse
BE712507D BE712507A (en)) 1965-12-29 1968-03-20

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Application Number Priority Date Filing Date Title
US517239A US3409534A (en) 1965-12-29 1965-12-29 Electrolytic material removal apparatus

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US3409534A true US3409534A (en) 1968-11-05

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US517239A Expired - Lifetime US3409534A (en) 1965-12-29 1965-12-29 Electrolytic material removal apparatus

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BE (1) BE712507A (en))
CH (1) CH456798A (en))
DE (1) DE1565555B1 (en))
GB (1) GB1159115A (en))
NL (1) NL6610484A (en))
SE (1) SE335940B (en))

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3658682A (en) * 1968-07-01 1972-04-25 Gen Electric Electrolyte supply system
US3793170A (en) * 1971-06-09 1974-02-19 Trw Inc Electrochemical machining method and apparatus
US3974050A (en) * 1971-10-12 1976-08-10 Kernforschungsanlage Julich Gesellschaft Mit Beschrankter Haftung Method of and apparatus for processing the surface of bodies
US4088557A (en) * 1977-07-01 1978-05-09 United Technologies Corporation Electrode assembly and machine for small-hole electrochemical drilling
US4115223A (en) * 1975-12-15 1978-09-19 International Standard Electric Corporation Gallium arsenide photocathodes
US5543032A (en) * 1994-11-30 1996-08-06 Ibm Corporation Electroetching method and apparatus
CN102179585A (zh) * 2011-05-20 2011-09-14 南京航空航天大学 基于毛细管阴极的小锥度微小孔电解加工装置及方法

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2538653C2 (de) * 1975-08-30 1982-08-12 MTU Motoren- und Turbinen-Union München GmbH, 8000 München Vorrichtung zum elektrolytischen Feinbohren
FR2573332B1 (fr) * 1984-11-20 1988-07-29 France Etat Armement Dispositif de decoupe de pieces conductrices de l'electricite par jet electrolytique et application a la recuperation d'echantillon

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1416929A (en) * 1921-11-07 1922-05-23 William E Bailey Art of electrolysis
US2767137A (en) * 1954-07-15 1956-10-16 Philco Corp Method for electrolytic etching
US2937124A (en) * 1955-06-23 1960-05-17 Philco Corp Method of fabricating semiconductive devices and the like
US3314875A (en) * 1962-07-24 1967-04-18 Gen Electric Electrode holder

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1337314A (fr) * 1962-01-31 1963-09-13 Nippon Kogaku Kk Procédé pour le travail électrolytique précis de métaux

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1416929A (en) * 1921-11-07 1922-05-23 William E Bailey Art of electrolysis
US2767137A (en) * 1954-07-15 1956-10-16 Philco Corp Method for electrolytic etching
US2937124A (en) * 1955-06-23 1960-05-17 Philco Corp Method of fabricating semiconductive devices and the like
US3314875A (en) * 1962-07-24 1967-04-18 Gen Electric Electrode holder

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3658682A (en) * 1968-07-01 1972-04-25 Gen Electric Electrolyte supply system
US3793170A (en) * 1971-06-09 1974-02-19 Trw Inc Electrochemical machining method and apparatus
US3974050A (en) * 1971-10-12 1976-08-10 Kernforschungsanlage Julich Gesellschaft Mit Beschrankter Haftung Method of and apparatus for processing the surface of bodies
US4115223A (en) * 1975-12-15 1978-09-19 International Standard Electric Corporation Gallium arsenide photocathodes
US4088557A (en) * 1977-07-01 1978-05-09 United Technologies Corporation Electrode assembly and machine for small-hole electrochemical drilling
US5543032A (en) * 1994-11-30 1996-08-06 Ibm Corporation Electroetching method and apparatus
CN102179585A (zh) * 2011-05-20 2011-09-14 南京航空航天大学 基于毛细管阴极的小锥度微小孔电解加工装置及方法
CN102179585B (zh) * 2011-05-20 2012-12-12 南京航空航天大学 基于毛细管阴极的小锥度微小孔电解加工装置及方法

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Publication number Publication date
DE1565555B1 (de) 1971-10-21
SE335940B (en)) 1971-06-14
CH456798A (de) 1968-07-31
GB1159115A (en) 1969-07-23
NL6610484A (en)) 1967-06-30
BE712507A (en)) 1968-07-31

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