Workholding for pulsed electrochemical machining

Patent metadata

Field	Value
Publication number	US-12459044-B2
Application number	US-202217661246-A
Country	US
Kind code	B2
Filing date	Apr 28, 2022
Priority date	Apr 28, 2022
Publication date	Nov 4, 2025
Grant date	Nov 4, 2025

Abstract

A pulsed electrochemical machining (pECM) system includes a pECM tool comprising a tool body defining a tool axis, the tool body comprising one or more electrodes, each of the one or more electrodes comprising an electrically conductive material and defining a working surface at a distal end of the tool axis configured to face a workpiece; an enclosure system configured to hold the workpiece, wherein the enclosure system comprises: a first clamp configured to grip a first end of the workpiece; a second clamp configured to grip a second end of the workpiece; and a backside support configured to support a span of the workpiece between the first end and the second end.

First claim

The invention claimed is:

1 . A pulsed electrochemical machining (pECM) system, comprising:
a pECM tool comprising a tool body defining a tool axis, the tool body comprising one or more electrodes, each of the one or more electrodes comprising an electrically conductive material and defining a working surface at a distal end of the tool axis configured to face a working surface of a workpiece; a pulsing power supply configured to output pulses of electrical energy via the one or more electrodes; an enclosure system configured to hold the workpiece, wherein the enclosure system comprises: a first clamp configured to grip a first end of the workpiece;
a second clamp configured to grip a second end of the workpiece; and
a backside support in physical contact with and configured to support a span of a non-working surface of the workpiece between the first end and the second end, wherein the backside support comprises:
a plurality of height adjustable pins that each support a portion of the span.

2 . The pECM system of claim 1 , wherein the workpiece comprises a coversheet for an airfoil of a gas-turbine engine.

3 . The pECM system of claim 2 , further comprising:
an electrolyte system configured to supply electrolyte to an interelectrode gap between the working surface of the one or more electrodes and a target surface of the workpiece, wherein a force induced by the supply of the electrolyte on the workpiece is opposed in part by the backside support.

4 . The pECM system of claim 3 , wherein the backside support supports at least a portion of the span that is opposite a portion of the target surface that is being machined by the pECM tool.

5 . The pECM system of claim 3 , wherein the backside support comprises:
a reservoir of fluid.

6 . The pECM system of claim 5 , wherein the fluid comprises the electrolyte.

7 . The pECM system of claim 1 , wherein the plurality of height adjustable pins are uniformly distributed.

8 . The pECM system of claim 1 , further comprising:
a locking mechanism configured to lock positions of the plurality of height adjustable pins.

9 . The pECM system of claim 1 , wherein the backside support comprises:
a block having a surface that corresponds to a surface of the workpiece that is opposite a target surface of the workpiece.

10 . A method for pulsed electrochemical machining (pECM) a workpiece, comprising:
gripping a first end of the workpiece having a target surface and a non-target surface; gripping a second end of the workpiece; supporting, by a backside support, a span of the workpiece that extends between the first end and the second end, wherein the backside support is in physical contact with the non-target surface of the workpiece; generating a pulsed direct current between one or more electrodes of a machining tool and the workpiece, wherein the machining tool comprises a tool body defining a tool axis, the tool body comprising the one or more electrodes, each of the one or more electrodes comprising an electrically conductive material and defining a working surface at a distal end of the tool axis configured to face the workpiece, wherein the backside support comprises a plurality of height adjustable pins that each support a portion of the span; delivering an electrolyte into an interelectrode gap between the working surface of the one or more electrodes and the target surface of the workpiece; and positioning the working surface of the one or more electrodes relative to the target surface of the workpiece to remove material from the target surface of the workpiece.

11 . The method of claim 10 , wherein the workpiece comprises a coversheet for an airfoil of a gas-turbine engine.

12 . The method of claim 10 , wherein supporting the span of the workpiece comprises opposing a force induced by the delivery of the electrolyte on the workpiece.

13 . The pECM system of claim 1 , wherein the system is not configured to machine, temporally in parallel, the working surface and the non-working surface.

14 . The pECM system of claim 1 , wherein the backside support forms a portion of a current path that electrically couples the workpiece to the power supply.

15 . The method of claim 10 , further comprising:
flipping, after removing material from the target surface of the workpiece, the workpiece over to remove material from the backside of the workpiece via the machining tool.

16 . A pulsed electrochemical machining (pECM) system, comprising:
a pECM tool comprising a tool body defining a tool axis, the tool body comprising one or more electrodes, each of the one or more electrodes comprising an electrically conductive material and defining a working surface at a distal end of the tool axis configured to face a working surface of a workpiece; an enclosure system configured to hold the workpiece, wherein the enclosure system comprises: a first clamp configured to grip a first end of the workpiece;
a second clamp configured to grip a second end of the workpiece; and
a backside support in physical contact with and configured to support a span of a non-working surface of the workpiece between the first end and the second end, wherein the backside support comprises a plurality of pedestals connected to the workpiece via an adhesive.

17 . The pECM system of claim 16 , wherein the adhesive comprises an ultraviolet (UV) curable adhesive.

18 . The pECM system of claim 16 , wherein the adhesive is electrically conductive.

19 . The pECM system of claim 18 , further comprising:
a power supply, wherein the adhesive forms a portion of a current path that electrically couples the workpiece to the power supply.

Assignees

• Rolls Royce Corp

Inventors

• Garner Rusty M
• Munoz Monica Sy
• Ward Damon
• Allen Anthony F

Classifications

• B23H3/10

  Supply or regeneration of working media · CPC title

• B23H9/10 Primary

  Working turbine blades or nozzles · CPC title

• B23H2300/10

  Pulsed electrochemical machining · CPC title

• F05D2300/507

  Magnetic properties · CPC title

• F05D2300/171

  Steel alloys · CPC title