Electrode assembly and electrochemical machining method

Patent metadata

Field	Value
Publication number	US-2024253141-A1
Application number	US-202218288481-A
Country	US
Kind code	A1
Filing date	Apr 27, 2022
Priority date	Apr 27, 2021
Publication date	Aug 1, 2024
Grant date	—

Abstract

An electrode assembly for electrochemically machining a cavity of a component is disclosed. The electrode assembly comprises: an electrode, a mounting body, and an urging means. The electrode comprises a plurality of conductive elements, including an outermost conductive element. The mounting body is coupled to the electrode and engageable with the component to align the electrode within the cavity. The urging means is configured to transition the electrode from a movable configuration to a conforming configuration. In the movable configuration the conductive elements are moveable relative to one another. In the conforming configuration adjacent conductive elements align to define a substantially continuous outer electrode surface.

First claim

1 . An electrode assembly for electrochemically machining a cavity of a component, the electrode assembly comprising:
an electrode comprising a plurality of conductive elements, including an outermost conductive element; a mounting body coupled to the electrode and engageable with the component to align the electrode within the cavity; and an urging means configured to transition the electrode from a movable configuration to a conforming configuration; wherein in the movable configuration the conductive elements are moveable relative to one another; and in the conforming configuration adjacent conductive elements align to define a substantially continuous outer electrode surface.

2 . The electrode assembly according to claim 1 , wherein the urging means comprises a flexible element.

3 . (canceled)

4 . (canceled)

5 . (canceled)

6 . (canceled)

7 . The electrode assembly according to claim 1 , wherein each of the conductive elements comprises:
a first end proximate the mounting body; and a second, opposing end, distal the mounting body;
wherein, for at least in board conductive elements, one or more of the first and second ends comprises an alignment feature configured to align the respective conductive element with the adjacent conductive element.

8 . (canceled)

9 . (canceled)

10 . (canceled)

11 . The electrode assembly according to claim 1 , wherein the conductive elements are hingeably connected to one another.

12 . (canceled)

13 . (canceled)

14 . The electrode assembly according to claim 1 , wherein a cross-section shape of the electrode is non-constant along a length of the electrode.

15 . (canceled)

16 . The electrode assembly according to claim 1 , wherein the mounting body is an alignment flange.

17 . The electrode assembly according claim 1 , wherein the mounting body comprises one or more electrolyte apertures extending therethrough.

18 . The electrode assembly according to claim 1 , wherein the mounting body comprises an integral busbar.

19 . The electrode assembly according to claim 1 , wherein the mounting body is integral with a first conductive element of the electrode.

20 . The electrode assembly according to claim 1 , wherein the mounting body comprises a plurality of electrolyte channels distributed around the electrode.

21 . (canceled)

22 . (canceled)

23 . The electrode assembly according to claim 20 , wherein the electrolyte channels are defined by one or more ribs.

24 . The electrode assembly according to claim 1 , further comprising an electrolyte conduit in electrical communication with the mounting body.

25 . (canceled)

26 . (canceled)

27 . (canceled)

28 . The electrode assembly according to claim 24 , wherein the electrolyte conduit has an extent of at least around six major dimensions of the cross-section of the conduit.

29 . The electrode assembly according to claim 1 , wherein the electrode is a first electrode; and
wherein a second electrode, comprising a respective plurality of conductive elements, is coupled to the mounting body.

30 . A method of electrochemically machining a cavity of a component using the electrode assembly according to claim 1 , the method comprising:
inserting the outermost, and successive, conductive elements of the electrode through an opening of the cavity and along the cavity whilst the electrode is in the movable configuration; coupling the mounting body to the component to align the electrode within the cavity, and actuating the urging means to transition the electrode from the movable configuration to the conforming configuration, the conductive elements thus defining the substantially continuous outer electrode surface which conforms to at least part of an internal wall of the cavity; and applying a negative charge to the electrode, and providing a flow of electrolyte through the cavity to remove material from the internal wall of the cavity.

31 . The method according to claim 30 , further comprising releasing the urging means, decoupling the mounting body from the component and withdrawing the electrode from the cavity, the electrode transitioning to the movable configuration as the electrode is withdrawn from the cavity.

32 . The method according to claim 30 , wherein a low power test is conducted before an operational power is supplied to the electrode.

33 . The method according to claim 30 , wherein an indicator is applied to the component during the electrochemical machining.

34 . The method according to claim 30 , wherein the cavity is a fluid conduit.

35 . The method according to claim 34 , wherein the component is a turbine housing or a compressor housing for a turbocharger, and wherein the cavity is a turbine housing volute or a compressor housing volute respectively.

36 . A computer program comprising computer executable instructions that, when executed by a processor, cause the processor to control an additive manufacturing apparatus to manufacture the electrode, or a conductive element thereof, according to claim 1 .

37 . A method of manufacturing an electrode, or a conductive element thereof, via additive manufacturing, the method comprising:
obtaining an electronic file representing a geometry of the electrode, or a conductive element thereof, according to claim 1 ; and controlling an additive manufacturing apparatus to manufacture, over one or more additive manufacturing steps, the electrode, or a conductive element thereof, according to the geometry specified in the electronic file.

38 . A component comprising a cavity electrochemically machined using the electrode assembly according to claim 1 .

39 . A component comprising a cavity electrochemically machined using the method according to claim 30 .

Assignees

• Cummins Ltd

Inventors

• Holroyd Robert L
• Roberts Thomas
• Sullivan Laura
• Holt Aaron Matthew
• Arbuckle Ivan Scott
• Dickinson Philip Neil

Classifications

• B23H9/14

  Making holes · CPC title

• B23H9/06

  Marking or engraving · CPC title

• B23H3/10

  Supply or regeneration of working media · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title