Electrolysis: processes – compositions used therein – and methods – Electrolytic erosion of a workpiece for shape or surface...
Patent
1996-09-30
1998-10-13
Valentine, Donald R.
Electrolysis: processes, compositions used therein, and methods
Electrolytic erosion of a workpiece for shape or surface...
205645, 205652, 205665, 205672, 204224M, 204225, B23H 300, B23H 914, B23H 732
Patent
active
058207449
ABSTRACT:
Electrochemical machining (ECM) techniques utilizing real-time parameter monitoring, alarms and feedback control for improved machining of a workpiece are disclosed. The ECM device utilizes one or more cathodes, an electrolyte and a positively charged workpiece to achieve electrolytic action. A number of controlling variables, such as cathode feed rate, electrolyte flow rate and voltage, are balanced in response to measured system parameters. The following parameters are preferably monitored in order to adjust the controlling variables: the drive parameters of feed rate and cathode depth; the pump parameters of flow rate and pressure; and the power components of voltage and current. The flow rate in each of the cathodes, or a corresponding Reynolds number, is preferably utilized to provide an alarm to the operator if a statistically significant change in flow is detected. The dynamic fluid resistance gradient across one or more of the gaps being machined is utilized to approximate the desired shape of the workpiece being machined in real time. The dynamic electrical resistance may be utilized to improve the shape approximation. The approximated shape values are utilized to provide feedback control of one or more of the controlling variables to obtain improved results. The dynamic fluid resistance is the difference between the total measured fluid resistance and the static fluid resistance, as obtained during a calibration procedure.
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