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EP4359589A1 - Dispositif et procédé de traitement électrolytique au plasma de la surface électroconductrice d'une pièce au moyen de jets d'électrolyte - Google Patents

Dispositif et procédé de traitement électrolytique au plasma de la surface électroconductrice d'une pièce au moyen de jets d'électrolyte

Info

Publication number
EP4359589A1
EP4359589A1 EP23744057.3A EP23744057A EP4359589A1 EP 4359589 A1 EP4359589 A1 EP 4359589A1 EP 23744057 A EP23744057 A EP 23744057A EP 4359589 A1 EP4359589 A1 EP 4359589A1
Authority
EP
European Patent Office
Prior art keywords
electrolyte
workpiece
jet
unit
processed
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.)
Pending
Application number
EP23744057.3A
Other languages
German (de)
English (en)
Inventor
Vincent Stepputat
Michael Penzel
Sam Schröder
Henning Zeidler
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.)
Bergakademie Freiberg
Original Assignee
Bergakademie Freiberg
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 Bergakademie Freiberg filed Critical Bergakademie Freiberg
Publication of EP4359589A1 publication Critical patent/EP4359589A1/fr
Pending legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25F—PROCESSES FOR THE ELECTROLYTIC REMOVAL OF MATERIALS FROM OBJECTS; APPARATUS THEREFOR
    • C25F3/00—Electrolytic etching or polishing
    • C25F3/16—Polishing
    • 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
    • B23H3/10—Supply or regeneration of working media
    • 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
    • B23H3/02—Electric circuits specially adapted therefor, e.g. power supply, control, preventing short circuits
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25F—PROCESSES FOR THE ELECTROLYTIC REMOVAL OF MATERIALS FROM OBJECTS; APPARATUS THEREFOR
    • C25F7/00—Constructional parts, or assemblies thereof, of cells for electrolytic removal of material from objects; Servicing or operating

Definitions

  • the invention relates to a device and a method for plasma electrolytic processing of an electrically conductive surface of a workpiece.
  • the device has an application unit for applying an electrolyte jet to the workpiece surface, a supply unit for at least temporarily supplying the application unit with the electrolyte required to generate the electrolyte jet and at least one electrode, which forms a counter electrode to the surface as a cathode during processing.
  • at least one voltage source is also provided, with which a voltage can be applied between the electrode and the surface to be processed, each of which is at least partially in contact with the electrolyte, during the processing of the workpiece surface.
  • the target surface properties are usually not achieved in the primary production step, so subsequent finishing or finishing is required. This includes, for example, polishing, cleaning, sterilizing, texturing and coating the surface as well as deburring and rounding workpiece edges.
  • the processes that change the surface properties through material removal are of considerable economic and technological importance.
  • the final processing of metal surfaces using cutting processes with a geometrically undetermined cutting edge, such as grinding or mechanical polishing, which enable low roughness and high gloss is known. These always require that the surface can be reached by a generally rotating tool, so that the processing of narrow, concave contours and inner surfaces is hardly possible.
  • the process principle always requires precise coordination of the relative position of the tool to the machined surface.
  • Plasma electrolytic processing processes are processes with which the nature of a workpiece surface that is at least temporarily in contact with an electrolyte is changed by applying an electrical voltage, whereby This change is enabled, favored or influenced by the formation of a plasma close to the surface.
  • plasma electrolytic oxidation is used, among other things, to produce wear-resistant surface layers, especially on light metals, in plasma electrolytic polishing the surface layer is changed by material removal. In comparison to electropolishing, this occurs using aqueous salt solutions instead of highly concentrated acids as an electrolyte, with the workpiece typically being immersed in such an electrolyte bath and contacted anodically.
  • the electrolyte in contact with the workpiece evaporates and forms a vapor skin surrounding it, which displaces the electrolyte solution from the workpiece surface.
  • the polishing voltage falling across the steam skin leads to partial ionization and the formation of a plasma.
  • the surface of the workpiece is evenly smoothed and at the same time freed from contamination through a combination of physical, chemical and electrochemical removal processes. In this way, particularly smooth and shiny surfaces can be created in a very short time and without mold-based tools. In addition, it is not necessary to pre-treat the respective workpiece or to remove any oils or lubricants that may be present on the surface.
  • plasma electrolytic processing can be used to create a workpiece surface whose tendency to corrode is inhibited.
  • the process is therefore not only suitable for reducing surface roughness, but also for, among other things, deburring, creating shine, passivating, cleaning, sterilizing and smoothing the surface profile.
  • a generic system for plasma polishing is known from DE 102006 016 368 B4.
  • the system described is suitable for cleaning and polishing electrically conductive workpiece surfaces and has an electrolyte container, a holder for the workpiece and a power supply to provide the voltage required for plasma electrolytic processing. Furthermore, a control for monitoring and setting the required current strength is provided, which sets the current strength depending on the speed at which the workpiece is immersed in the electrolyte container.
  • Another disadvantage is that the required current strength must be provided in proportion to the component surface, since the underlying operating principle requires a material and electrolyte-specific current density on the workpiece surface, which is typically in the range of 0.2 A/cm 2 to 0.5 A/ cm 2 lies.
  • the process is technologically and economically viable Limits are set regarding the component size, which rarely exceeds the dimension of a cube with an edge length of 20 cm.
  • the use of plasma electrolytic processing processes for large components that require large processing systems is often uneconomical. This is especially true if only individual surfaces or contours are to be processed instead of the entire component surface, such as when deburring. The processing of the entire surface inherent in plasma electrolytic polishing in the electrolyte bath then regularly leads to a multiple of the power requirement, the investment requirement and the processing effort than would be necessary to meet the surface requirements.
  • One approach to circumventing the limitation of the workable component size is to transfer it to a selective process, as is known from DE 10 2014 108 447 A1.
  • the anodically poled workpiece is now passed through this trough, with insulating strips running transversely to the workpiece delimiting the surface in contact with the electrolyte, thus creating a polishing bath that only has a selective effect. While such a device removes the process limit of the maximum component size, geometrically complex components cannot be processed or can only be processed to a very limited extent. In addition, it does not allow selective processing of individual surfaces outside of a one-dimensionally defined overall section.
  • a special plasma electrolytic machining process involves the use of an electrolyte jet instead of an electrolyte bath, in which case the electrolyte nozzle, which directs an electrolyte jet onto the workpiece, also forms the cathode. Material removal only occurs at the point where the electrolyte jet hits the surface of the workpiece. This limits the maximum current required and allows processing to be focused on selected areas.
  • a system for implementing the previously described method is known from DE 20 2019 001 138 U1.
  • This document describes a system for plasma polishing an electrically conductive surface of a workpiece, the system having a holding device for holding the workpiece and an electrolyte container from which the electrolyte is conveyed to a nozzle unit.
  • the nozzle unit is used to process the workpiece surface directed electrolyte jet is generated. This can be directed as a free jet outside the electrolyte tank onto the workpiece and used for plasma electrolytic processing (jet plasma polishing), or it can be positioned in the electrolyte tank itself.
  • the workpiece is processed, as is known from the prior art, in an electrolyte bath (bath plasma polishing), whereby the directed flow of the electrolyte onto a surface of the workpiece specifically influences the shape of the steam skin and thus the process control.
  • an electrolyte bath bath plasma polishing
  • the invention is based on the object of specifying a technical solution with which comparatively large areas and / or different, complex contours can be processed plasma electrolytically in a suitable manner.
  • it should be possible to produce high-quality surfaces quickly, reliably and repeatably, even for workpieces with different geometries and/or complex surface contours.
  • It should also be possible to deburr comparatively large components, taking both technical and economic constraints into account.
  • the technical solution to be specified should generally be suitable for use in industrial processes, especially in series production, and should be able to be integrated into industrial production using relatively simple means and in an economically sensible manner. Furthermore, the technical solution to be specified should be suitable in order to be able to be adapted to different machining tasks, in particular to the machining of differently shaped workpieces, without significant design effort. Furthermore, a processing system should be specified that can be manufactured and operated effectively, taking into account the known design principles and from an economic point of view. The energy requirement that is required for the plasma electrolytic processing of workpieces with differently shaped workpiece surfaces should be minimized and, in addition, current peaks should be limited as simply as possible. The task described above is achieved with a device according to claim 1 and a method according to claim 13. Advantageous embodiments of the invention are the subject of the dependent claims and are explained in more detail in the following description with partial reference to the figures.
  • the invention relates to a device for plasma electrolytic processing of an electrically conductive, in particular a metallic, surface of a workpiece, which has an application unit for applying an electrolyte jet to the surface, via a supply unit for at least temporarily supplying the application unit with the electrolyte required to generate the electrolyte jets at least one electrode, which forms a counter electrode to the surface, in particular a cathode, during processing and at least one unit with which the electrode and the surface can be supplied with electrical energy during processing in such a way that between the electrode and the surface to be processed When touched, a current flows through the electrolyte.
  • the device is characterized in that the application unit is designed to generate a first and at least one separate second electrolyte jet, which have different jet shapes, jet directions, jet effective areas, arrangements in space, jet compositions and / or flow properties and around the surface of the Workpiece to be applied at the same time or in succession with the first and at least one second electrolyte jet.
  • the essential idea of the invention is therefore based on providing an application unit via which at least two beams with different properties, in particular from different directions and with different effective ranges, can be applied to the workpiece surface to be processed at the same time or one after the other.
  • a jet effective area is understood to mean an area of the surface of a workpiece to be machined, onto which an electrolyte jet impinges, so that at least one surface property changes at least partially in this area.
  • the surface of a workpiece is simultaneously or successively treated with the help of at least two electrolyte jets, which differ in terms of at least one property, their orientation, their arrangement in space and/or the beam effective area on which the at least two electrolyte jets act.
  • the at least two electrolyte jets initially generated by the application unit are separate jets which preferably emerge from different outlet openings of the application unit and do not mix on the flow path between the application unit and the jet effective areas on the workpiece surface to be treated, in particular not to form a homogeneous jet mix.
  • the at least two separate electrolyte jets impinge on two jet effective areas on the workpiece surface, which do not or only partially overlap.
  • the separate electrolyte jets provided according to the invention are therefore distinguished from the division of a current into individual current threads, as is achieved, for example, by a perforated plate or an aerator, in that they are always independent jets whose properties can be adjusted as required.
  • a jet can be briefly separated into different flow threads using a perforated plate or an aerator, but after flowing through the flow obstacle in the form of a perforated plate or an aerator, these merge back into a common jet.
  • at least two electrolyte jets are generated and directed onto a workpiece surface, so that at least partially different jet effective areas can be processed on the workpiece surface. What is important here is that the properties of the at least two separate electrolyte jets can be adjusted differently, thus enabling particularly needs-based processing of workpieces, even with complex surface contours.
  • the at least two electrolyte jets are aligned or aligned in such a way that their projection surface corresponds at least in some areas to the shape and/or contour of the surface to be processed.
  • processing is understood to mean material removal of the surface material, cleaning, changing at least one property of the surface layer and/or applying a material to the surface, in particular polishing, deburring, oxidizing, degreasing and/or deoiling.
  • the supply unit it is advantageous if it has at least one conveying element, for example in the form of a centrifugal, impeller or gear pump, which enables at least almost pulsation-free delivery of the electrolyte to the delivery unit. This is advantageous because pulsations of an electrolyte jet applied to the workpiece surface impair the stable formation of the steam skin on the workpiece surface.
  • the device is a stationary or a portable device for the appropriate processing of electrically conductive, in particular metallic, surfaces. It is therefore conceivable that the system is designed as a stationary machine tool for processing workpiece surfaces or as a portable, preferably hand-held machine tool, which is also brought to the workpiece being processed.
  • the technical solution according to the invention it is comparatively possible It is possible in a simple manner to process a given contour of an electrically conductive workpiece surface, preferably in an automated plasma electrolytic manner, in particular to polish and/or deburr it. Due to the flexible design of the device according to the invention, electrolyte jets with different properties can be applied to a surface to be processed in three-dimensional space at the same time or at a time interval from one another.
  • the application unit is designed such that at least two electrolyte jets from different directions can be applied to the workpiece surface to be processed at the same time or at a time interval.
  • the delivery unit preferably has at least two outlet openings, in particular nozzles, via which an electrolyte jet can be applied in a targeted manner to the workpiece surface to be processed.
  • the outlet openings are preferably arranged or to be arranged in such a way that surfaces with different contours can be exposed to at least one of the electrolyte jets for surface processing at a process-specific angle. This angle should preferably be chosen so that the electrolyte jet is aligned along the surface or contour normal. Due to accessibility, surface geometry or the processing goal, among other things, it can also be advantageous to choose a different angle. In this context, it is conceivable that the entire delivery unit and/or individual outlet openings can be moved in a targeted manner.
  • the application unit has at least one adjusting element through which the jet shape, jet direction, jet effective range, jet composition and/or a flow property of the electrolyte jet can be changed.
  • an adjusting element thus ensures that electrolyte jets with different properties and adapted to the respective needs or the respective processing task can be applied to the surface of a workpiece.
  • an adjusting element is designed to change the size, shape and/or orientation of an outlet opening, in particular a nozzle, as required. It is generally conceivable to vary the orientation of an electrolyte jet, the jet shape, the flow speed and/or the volume flow using such an outlet opening.
  • An at least temporary interruption or a pulsed application of at least one of the electrolyte jets is also conceivable.
  • the actuating element has at least one valve and/or a metering unit through which a composition of the electrolyte jet discharged by the application unit can be changed.
  • an adjusting element has at least one adjusting element, a mixing element and/or a heating element in order to suitably adapt the flow properties and/or the temperature of the electrolyte to the requirements of the respective processing task.
  • an electrolyte temperature of 60 °C to 95 °C is preferred, as this reduces the energy required until the electrolyte evaporates. This can be achieved, for example, with screw-in heaters, instantaneous water heaters, ceramic heaters or a combination of these.
  • plasma electrolytic oxidation is also possible with electrolytes at room temperature.
  • At least one measuring unit is for continuous or discontinuous measurement of at least one property of the surface, for determining a distance between the application unit and/or an outlet opening of the application unit and the surface and/or for determining the relative position of the application unit (4 ) provided to the surface.
  • At least one control unit is preferably provided, through which a control signal can be generated depending on a property of the workpiece surface, a measured value generated by the measuring unit and/or a setpoint value and sent to the delivery unit for changing the beam shape, beam direction, the beam effective range, the beam composition, the arrangement the electrolyte jets in space, the activation or deactivation of at least one electrolyte jet and / or a flow property of at least one of the electrolyte jets can be transmitted.
  • a control unit which is freely programmable in an advantageous manner, thus enables a particularly flexible use of a device designed according to the invention.
  • the control unit is preferably designed in such a way that the individual required process parameters, such as temperature, flow shape, flow velocity, volume flow and/or composition of at least one of the electrolyte jets, can be changed as required.
  • the control unit is designed to vary the voltage applied between the electrode and the workpiece surface as required, in particular to set the voltage to a value above or below a limit value.
  • the limit value is selected so that at a voltage above the limit value, plasma electrolytic processing of the workpiece surface takes place, while at a voltage below the limit value, electrochemical processing of the workpiece surface takes place.
  • the roughness can first be reduced electrochemically at high removal rates and then a high-quality, shiny surface can be created using plasma electrolysis by changing the voltage.
  • a combination of such a control unit with at least one of the previously described control elements is particularly advantageous in order to be able to generate at least two electrolyte jets with different properties in a particularly flexible and effective manner and to apply them to the workpiece surface to be processed and/or to change the type of surface processing by changing the voltage .
  • the measuring unit has at least one measuring unit for the continuous or discontinuous measurement of at least one property of the workpiece surface, in particular the surface roughness, and/or for the continuous or discontinuous determination of the relative position of the application unit to the surface.
  • the measuring unit is aligned with the beam effective area.
  • at least two measuring units can be provided, which detect at least one area before and one after the jet effective area, particularly in the event of a planned relative movement of the application unit to the workpiece surface.
  • the properties of the surface can be recorded in particular optically, for example through a gloss measurement using a camera or the laser-based recording of a roughness profile. To determine the relative position, measurement via ultrasound can also be considered.
  • a combination of such a measuring unit with at least one of the control units described above and one of the control elements described above is particularly advantageous in order to be able to use the measurement results directly to control the machining process.
  • the relative speed of the application unit to the surface, the processing voltage or the jet composition of the electrolyte can be changed depending on a comparison of the measurement of the measuring unit to a target state.
  • such an arrangement allows the continuous recording of data for the purpose of effective quality assurance.
  • the delivery unit has at least two outlet openings, in particular two nozzle elements, for the delivery of electrolyte jets.
  • these outlet openings and/or the elements forming them are movably arranged, have different dimensions, can be supplied with the electrolyte separately from the supply unit and/or are designed in such a way that at least two electrolyte jets with different jet shapes and/or flow properties can be applied to the workpiece surface.
  • the delivery unit can be adapted flexibly and yet with comparatively simple means to the existing requirements, in particular the material to be processed and the surface contour, depending on the respective processing task.
  • suitable fixing and/or movement devices are provided in order to produce a relative movement between the workpiece surface to be machined and the delivery unit, in particular at least one outlet opening for an electrolyte jet.
  • a corresponding relative movement can be initiated, for example, by either moving the workpiece whose surface is to be machined and/or at least partially moving the delivery unit.
  • the application unit and/or at least parts of the supply unit are arranged on at least one robot arm.
  • the application unit and/or at least parts of the supply unit are arranged on at least one robot arm.
  • a particularly flexible movement of the delivery unit relative to the workpiece surface to be processed can be made possible by using an industrial robot.
  • the use of axis kinematics is also possible.
  • At least one adjustment unit is provided for changing a distance between the surface of the workpiece to be machined and at least one outlet opening of the delivery unit and/or a relative arrangement of at least one outlet opening of the delivery unit and the workpiece surface to be machined.
  • suitable movements of the delivery unit and/or the workpiece can be initiated using a robot arm and/or axis kinematics.
  • polishing current that occurs at a given electrical voltage and the electrical voltage required to generate a required polishing current can be specifically adjusted.
  • a small distance is advantageous in terms of the geometric accuracy of the jet shape to the outlet opening, particularly in the case of electrolyte jets that do not run along the force of gravity.
  • a minimum distance must be observed to ensure that sparks do not flash over.
  • the polishing current flowing during the processing of the workpiece surface is measured. The corresponding measured value can then be used in a suitable manner to control or even regulate the machining process.
  • the process is running at least almost error-free. If, on the other hand, the current intensity changes sharply at times, i.e. the corresponding value repeatedly rises sharply, in particular upwards towards a larger value, it is preferably concluded that the steam skin collapses and that a new ignition occurs afterwards.
  • quality assurance can advantageously be implemented and/or the measured values obtained and/or values derived therefrom can be used to change a property of the adjusting element and/or the adjusting means and thus to influence the surface processing process in a targeted and needs-based manner.
  • an electrode surrounds the electrolyte jet at least in some areas.
  • the electrode is designed as an electrically conductive piece of pipe, which surrounds the electrolyte jet in the area of the outlet opening and thus forms the electrode in a suitable manner.
  • the delivery unit is designed to be electrically insulating and has at least individual electrically conductive areas which, during operation, form the counter electrodes to the workpiece surface to be processed as electrodes, in particular cathodes.
  • the electrically conductive areas of the delivery unit are preferably designed as pipe sections, with the respective outlet opening for the exit of an electrolyte jet being provided at the end of the pipe sections.
  • the electrical field and thus the areas of the workpiece surface to be machined can be varied by specifically switching the electrically conductive areas provided on the delivery unit on and off. It is also conceivable that the entire delivery unit is designed to be electrically conductive and forms the electrode of the device according to the invention during a processing process.
  • the number and design of the electrodes always take into account that the cathode area should be larger than the anode area for safe and stable operation of a plasma polishing system, with a ratio of at least 5:1 being preferred.
  • the flow of an electrolyte at at least one outlet opening of the delivery unit can be switched on and off as required, i.e. pulsable.
  • the supply of electrical energy to the electrode and to the surface to be processed can be changed using at least one adjusting means.
  • the adjusting means is designed in such a way that the supply of electrical energy is at least temporarily completely interrupted or only a change in the current strength or voltage occurs.
  • a direct voltage of 200 V to 450 V is preferably applied between the electrode and the surface to be processed. In this way, a workpiece surface can be polished and/or deburred in a particularly suitable manner. If a voltage is reduced, for example to a value of 120 V, the workpiece surface is no longer processed using plasma electrolysis, but rather electrochemically. Since electrochemical machining involves a larger amount of material being removed from the workpiece surface per unit of time, the type of machining, in particular the size or speed of material removal, can be specifically changed by changing the voltage.
  • the supply unit has an electrolyte supply, via which electrolyte is supplied to the dispensing unit, an electrolyte discharge, via which electrolyte discharged by the dispensing unit is at least partially removed, and a processing unit, via which at least one property of the discharged electrolyte, in particular the temperature , the pH value, the conductivity and/or the turbidity can be changed.
  • the supply unit according to this embodiment is advantageously designed in such a way that the electrolyte is first applied by the application unit to the workpiece surface to be processed, then collected and advantageously reprocessed so that the electrolyte can be used again for processing the workpiece surface.
  • the electrolyte removal preferably has a blower unit, compressed air unit and/or a suction system, so that the electrolyte is sucked off and/or blown away after it hits the surface to be processed.
  • the electrolyte that has hit the surface is specifically sucked off or blown away and removed via a drain so that it can possibly be reused after processing. In this way, erosion phenomena outside the targeted effective area are prevented from occurring in surrounding areas.
  • at least one sensor unit is provided with which at least one property of the electrolyte, especially the conductivity, the pH value, the turbidity and/or the temperature, can be detected.
  • the salt content of the electrolyte used is measured via a conductivity measurement and raised back to the required level as required using a suitable dosing unit. Further measures can also be initiated, such as the appropriate addition of at least one pH regulator and/or the cleaning of the electrolyte, for example using suitable filter elements, such as a cyclone separator, filter, or the addition of chemically active substances.
  • the electrolyte can be used over a comparatively long period of time and thus particularly economical operation of the device according to the invention can be achieved.
  • the device according to the invention has containers for storing substances that are required for metering and/or cleaning.
  • a cleaning unit is provided which enables cleaning of the delivery unit and/or the outlet openings, with cleaning preferably taking place as soon as the electrolyte is changed.
  • the device has at least one emitter with which sound waves and/or electromagnetic waves can be coupled into at least one of the electrolyte jets at least temporarily.
  • an emitter With the help of such an emitter, it is possible to couple sound waves and/or electromagnetic waves into at least one electrolyte jet, in particular in order to change the processing of the workpiece surface or to bring about an additional force input into the surface.
  • a corresponding effect on the surface can therefore be carried out using sound waves, in particular to influence the formation of the vapor skin, or with suitable electromagnetic radiation, for example high-energy laser radiation.
  • a light beam with a specific color for example by means of an LED
  • a corresponding light beam coupled into at least one electrolyte beam can therefore represent a warning for a user and advantageously forms part of a special safety device.
  • a device according to the invention is combined with further components, in particular in order to be able to realize effective integration into an industrial manufacturing process, combined with maintenance-free operation over the longest possible period of time.
  • an electrolyte concentrate container for storing at least one concentrate, the process-ready electrolyte being advantageously produced by mixing the concentrate with water, preferably with deionized water.
  • a corresponding production can preferably be carried out automatically. It is also conceivable to supplement a corresponding manufacturing process with the processing process described above.
  • a device for preferably continuously carried out processing can in turn have special components, such as a filter system for suspended particles, in particular with a cyclone filter, a metering unit for metering in precipitants and/or an electrolysis cell.
  • a container can be provided for storing pH regulators in order to acidify the electrolyte using a dosing unit during the process.
  • a storage container for at least one cleaning agent, so that the delivery unit, especially the at least one outlet opening, can preferably be cleaned automatically. Cleaning preferably takes place when the electrolyte is changed.
  • elements are provided for moving the workpiece before, after or during machining of the workpiece surface, which at the same time enable the transfer of electrical energy to the workpiece surface to be machined.
  • Such movement means can, for example, be designed as rollers that are pressed against the workpiece with a suitable pressure.
  • At least one unit is provided via which air and/or at least one gas can be introduced into at least one of the electrolyte jets at least temporarily.
  • the unit for introducing air and/or gas into an electrolyte jet preferably has at least one suitable jet regulator.
  • at least one outlet opening of the delivery unit has an exchangeable insert through which the Injection or suction of air and / or gas into an electrolyte jet in the area of the outlet opening is at least favored.
  • At least one of the outlet openings has a suitable internal structure, in particular a surface structure, which enables a suitable supply of air and/or gas into the electrolyte jet and/or the formation of air and/or gas bubbles in the electrolyte jet.
  • an electrically insulating spacer is provided in the area of at least one of the outlet openings of an application unit, which at least partially encloses the electrolyte jet and thus moves the effective outlet opening of the free jet closer towards the workpiece surface. The remaining distance can be reduced to zero, so that the spacer creates a direct, electrically insulating connection to the workpiece surface.
  • Such a spacer is preferably designed to be tubular at least in sections, so that the electrolyte jet impinges on the workpiece surface to be machined through such a spacer. A targeted application of an electrolyte jet therefore takes place, in which the distance to be overcome by the free jet can be reduced to zero.
  • At least one outlet opening of the delivery unit has a suitable surface structure on its inside in order to produce a desired flow shape of the electrolyte jet.
  • the effective cathode surface is increased due to a structured surface in the area of the outlet opening.
  • deterministic structures such as networks, grids and/or pipe texturing, as well as stochastic structures, for example in the form of sintered and/or sponge-like structures, are conceivable as surface structures.
  • These surface structures which are preferably selected depending on the respective processing task, can also be used in the form of exchangeable inserts in an outlet opening of a delivery unit.
  • storage units such as accumulators or capacitors, in particular supercapacitors
  • storage units such as accumulators or capacitors, in particular supercapacitors
  • peak current loads can occur particularly during the ignition process at the beginning of processing.
  • Corresponding peak loads can be at least partially reduced using such electrical energy storage systems.
  • the power consumption of a device according to the invention depends on the power output of the available decoupled from the electrical network.
  • the storage elements in such a way that the current intensity provided by them can be maintained over a longer period of time, in particular the processing time of a workpiece.
  • a system limited to 150 A processing current due to the connected load can be used by appropriate charging to process workpieces that require the provision of 200 A processing current.
  • the invention also relates to a method for plasma electrolytic processing of an electrically conductive, in particular metallic, surface of a workpiece, in which at least one electrolyte is conveyed to an application unit, via which a surface of a workpiece is at least temporarily exposed to an electrolyte jet, and in which an electrical voltage is applied between the surface of the workpiece to be machined and an electrode that at least partially touches the electrolyte, so that the electrode forms a counter electrode, in particular cathode, to the surface of the workpiece, which preferably represents the anode, during processing.
  • the method according to the invention is characterized in that the surface of the workpiece is exposed via the application unit simultaneously or in succession to a first and at least a second electrolyte jet, which have different jet shapes, jet directions, jet effective ranges, jet compositions and / or flow properties.
  • the method according to the invention is therefore essentially characterized by the fact that the surface of a workpiece to be processed is processed simultaneously or one after the other with electrolyte jets of different properties. During processing, material is again removed, surface cleaned, a change in at least one surface property and/or material is applied.
  • the electrolyte jets are preferably discharged from a movable, preferably from a plurality of movable, outlet openings in the direction of the workpiece surface to be machined.
  • the at least two electrolyte jets initially generated by or in the delivery unit are separate jets which are preferably delivered from different outlet openings of the delivery unit and do not mix on the flow path between the delivery unit and the jet effective areas on the workpiece surface to be treated, in particular do not mix into a homogeneous stream.
  • the at least two separate electrolyte jets impinge on two jet effective areas on the workpiece surface, which do not or only partially overlap.
  • the separate electrolyte jets provided according to the invention are therefore distinguished from the division of a current into individual current threads, as is achieved, for example, by a perforated plate or an aerator, in that they are always independent jets whose properties can be adjusted as required.
  • a jet can be briefly separated into different flow threads using a perforated plate or an aerator, but after flowing through the flow obstacle in the form of a perforated plate or an aerator, these merge back into a common jet.
  • at least two electrolyte jets are generated and directed onto a workpiece surface, so that at least partially different jet effective areas can be processed on the workpiece surface. What is important here is that the properties of the at least two separate electrolyte jets can be adjusted differently, thus enabling particularly needs-based processing of workpieces, even with complex surface contours.
  • the surface to be processed is exposed to electrolyte jets that are directed onto the surface from different directions.
  • the electrolyte jets can be interrupted as needed and/or the properties of the electrolyte jets can be varied.
  • it is advantageous if the surface of the workpiece to be processed is moved relative to the delivery unit. A relative movement can be generated either by moving the delivery unit or at least one outlet opening of the delivery unit and/or the workpiece.
  • the electrolyte is at least partially collected after application to the surface of the workpiece, the collected electrolyte is processed by changing at least one property and re-applied to the surface of the workpiece in the prepared state.
  • the electrolyte is conveyed in a circuit, with one Temporary storage in a tank is conceivable. In this way, particularly effective processing of a workpiece surface is possible over a comparatively long period of time due to the use of an electrolyte.
  • substances that are required for the preparation and/or cleaning of the electrolyte are stored in suitable containers and, if necessary, preferably using a suitable regulation or control, in particular to increase the salt content and/or reduce the pH Value, to be added.
  • the design of the delivery unit in particular its shape, the arrangement of the at least one outlet opening and/or the adjusting elements for changing at least one property of an electrolyte jet, is designed such that the outer contour of the delivery unit and/or the projection surfaces of the The electrolyte jets applied at least almost completely depict the shape of the surface of a workpiece to be processed.
  • the delivery unit is arranged stationary, for example on a machine frame, and the workpiece to be processed is inserted in an automated or semi-automated manner.
  • the application unit and a voltage source are preferably activated, so that a plurality of electrolyte jets are applied to the surface to be machined simultaneously or one after the other and a voltage is created between the electrode and on the workpiece surface. Due to the formation of a partially ionized gas shell, a plasma stabilizes on the surface of the workpiece and the desired processing occurs, in particular material removal.
  • the delivery unit and/or individual delivery openings are moved at least temporarily relative to the workpiece. So it is conceivable that after the workpiece has been moved in, they are first moved into a machining position and then moved back to the initial state after the machining process has been completed. Furthermore, continuous processing of a workpiece is conceivable, in which both the workpiece and at least parts of the delivery unit, such as individual outlet openings, are moved. In general, continuous processing of a workpiece, for example by moving the workpiece, as well as processing in several discrete steps is conceivable. Such a division into discrete processing steps can preferably be carried out in such a way that they have the same electrical power requirement as possible and the network is loaded as evenly as possible by the method. In addition, it is conceivable that the electrolyte supply and/or the energy supply for generating an electrical voltage is at least temporarily interrupted between individual processing steps, in particular in order to be able to implement an optimal process with regard to economical production.
  • the device according to the invention and the method according to the invention can be used advantageously for deburring metallic workpieces.
  • workpiece surfaces can be polished, sterilized and/or cleaned using the solution according to the invention.
  • a plasma electrolytic oxidation (PEO) takes place on the workpiece surface to be processed.
  • PEO plasma electrolytic oxidation
  • a voltage of approximately 200 V is preferably applied between the electrode and the workpiece surface to be processed.
  • workpiece processing is carried out by using a first electrolyte and a first voltage profile in a first step in order to effect a targeted material removal from the surface to be machined, while then in a second process step using a second electrolyte and a second voltage profile a plasma electrolytic coating, or a plasma electrolytic oxidation (PEO) takes place.
  • PEO plasma electrolytic oxidation
  • an electrically conductive, in particular metallic surface is not only deburred and/or polished, but further material removal is also realized.
  • the processing of a workpiece surface is carried out over a longer period of time, for example to create a rounding in the area of a workpiece contour or to smooth the surface profile, as is regularly the case with additive manufactured metal components is required.
  • either the dwell time of an outlet opening over the area of the workpiece surface to be processed is extended and/or the voltage is briefly reduced. This reduces the effects on the workpiece surface caused by plasma electrolytic processing and shifts the active principle in favor of electrochemical processing of the surface, which in turn is accompanied by a significantly higher material removal rate.
  • a corresponding change in the flow velocity of at least one electrolyte jet can take place independently of the number, shape and size of the outlet openings of an application unit.
  • At least one of the electrolyte jets is not directed as a free electrolyte jet onto the surface of the workpiece, but rather a spacer, which is not electrically conductive, is arranged between the outlet opening of an application unit and the workpiece surface.
  • a spacer is preferably made of ceramic, plastic and/or glass.
  • the processing of a workpiece surface is carried out using the method according to the invention with a stationary delivery unit, which is preferably part of a quick-clamping device, whereby after the workpiece to be processed has been properly fixed, the required processing position of the surface to be processed is already set relative to the delivery unit and the required electrical contacting is manufactured.
  • a feed movement of the workpiece is achieved at least temporarily using a roller system, the rollers advantageously being electrically conductive at the same time and enabling the transfer of electrical energy to the workpiece surface to be machined.
  • suitable sliding contacts for transmitting electrical energy to the workpiece surface to be machined.
  • a special embodiment of the invention provides that after processing a workpiece surface and / or between individual processing steps with material removal, material change or material application, at least one cleaning, drying and / or testing step is carried out, in particular with a camera, preferably automatically. Cleaning is preferably carried out with deionized water and/or ethanol.
  • the workpiece is preheated before processing in order to reduce the temperature difference to the electrolyte and to ensure process conditions that are as constant as possible over the entire processing time.
  • This is preferably done in a temperature-controlled fluid, which can also be the electrolyte itself.
  • it is also conceivable, for example, to preheat the workpiece via induction and, especially when selectively processing individual surfaces, via infrared radiators.
  • a further special embodiment of the invention provides that the electrolyte is at least partially collected after application to the surface of the workpiece, processed by changing at least one property of the collected electrolyte and re-applied to the surface of the workpiece in a prepared or unprocessed state.
  • an electrical voltage prevailing between the electrode and the surface to be processed before, during or after the processing of the surface at least one processing and / or process parameter, an electrical voltage prevailing between the electrode and the surface to be processed, a strength of a current flowing between the electrode and the surface to be processed , a distance between the delivery unit and/or an outlet opening of the delivery unit and the workpiece surface, the supply of electrolytes, a movement of the workpiece, a movement of the delivery unit and/or at least one setting of an emitter with which at least temporarily sound waves and/or electromagnetic waves are coupled into at least one of the electrolyte jets, measured and/or adjusted.
  • Fig. 1 First embodiment of a device designed according to the invention with a stationary dispensing unit and
  • Fig. 2 second embodiment of a device designed according to the invention with an at least partially movable delivery unit.
  • Fig. 1 shows a schematic top view of a first embodiment of a device 1 designed according to the invention for plasma electrolytic processing, preferably for deburring and / or polishing, of a surface 2 of a workpiece 3.
  • the device 1 shown has a supply unit 5, which is a delivery unit 4 supplies the electrolyte required for plasma electrolytic processing of a workpiece surface 2.
  • the supply unit 5 has a pump which, during operation, delivers the electrolyte from a storage container 16 with almost no pulsation to several outlet openings 10 of the delivery unit 4 in the form of nozzles.
  • the delivery of the electrolyte begins after the workpiece 3, the surface 2 of which is to be processed, has been fixed in the processing position, with a plurality of electrolyte jets from the individual outlet openings 10 striking the workpiece surface 2 to be processed from different directions.
  • the number of outlet openings 10 through which the electrolyte is discharged, as well as their design and orientation, is selected depending on the contour of the workpiece surface 2 to be machined and the machining task. According to the exemplary embodiment shown in FIG. 1, a workpiece 3 previously produced in mechanical series production is to be deburred using the device 1 according to the invention.
  • the device 1 shown also has a control unit 9, with which the supply unit 5, but also an electrical energy source 7 used as a voltage source, as well as the individual control elements 8 of the device 1, with which the application of electrolyte jets and the properties of the electrolyte jets are adjusted as required can be changed, controlled.
  • a measuring unit 22 with suitable sensors for continuous or discontinuous Measurement of at least one property of the surface 2, in particular the surface roughness, is provided for determining a distance between the application unit 4 and the surface 2 and/or for determining the position and/or orientation of the application unit 4 relative to the surface 2.
  • the measuring unit 22 and the control unit exchange data unidirectionally or bidirectionally via a data transmission link that can be wireless and/or wired.
  • a data transmission link that can be wireless and/or wired.
  • the electrolyte stored in a storage container 16 is preheated using a heating element 18 and then conveyed to the individual outlet openings 10 via the electrolyte supply 13 by means of a plurality of pumps, so that the individual outlet openings 10 can be supplied with the electrolyte separately.
  • the electrolyte is also supplied to the outlet openings 10 via adjusting elements 8, such as valves, with which the flow properties can be varied in a targeted manner. At least two electrolyte jets with different properties are applied simultaneously or one after the other to the workpiece surface 2 to be machined via the outlet openings 10.
  • a direct voltage of 200 V to 450 V is applied between at least one electrode 6, which according to the exemplary embodiment shown in FIG. 1 is formed by a piece of pipe, the end of which forms the respective outlet opening 10, and the workpiece surface 2.
  • the electrolyte jet hits the workpiece surface 2 to be machined, gas or vapor is formed and a gas-plasma shell forms on the surface 2, under which the desired material is removed.
  • the electrolyte After the electrolyte has hit the workpiece surface 2, it is sucked off by means of an electrolyte removal 14 of the supply unit 5 and fed to a processing unit 15 for electrolyte processing.
  • suspended particles are removed using a cyclone filter.
  • the turbidity, the pH value and the electrical conductivity of the removed electrolyte are then measured using at least one sensor unit 17. If the electrolyte is particularly dirty, a precipitant is added from a tank via a dosing unit in order to cause a precipitation reaction in the electrolyte, and the electrolyte is transferred to a separate processing unit. tank pumped over. Furthermore, depending on the measured values recorded for the conductivity and the pH value of the electrolyte, salt, for example ammonium salt, and/or a pH regulator is added from appropriate storage containers with suitable metering units 19 if necessary. The prepared electrolyte then returns to the storage container 16. A temperature sensor 20 and a heating element 18 are provided in the area of the storage container 16, so that the electrolyte is always heated to the required temperature before it is sent to the delivery unit 4 with the plurality of outlet openings 10 is supplied.
  • the workpiece surface 2 is processed by fixing or clamping the workpiece 3 in the area of the delivery unit 4 of the device 1 designed according to the invention.
  • the workpiece 3 is thus moved into the intended position for processing and fixed in this position.
  • the individual nozzle-shaped outlet openings 10 are then extended into their processing position.
  • the individual outlet openings 10 of the application unit 4 and thus the projection surfaces of the electrolyte jets delivered through them completely represent the shape of the surface 2 of the workpiece 3 to be processed.
  • the outlet openings 10 are moved back to their rest position, so that the distance between the workpiece 3 and the outlet openings 10 increases. The fixation of the workpiece 3 is then released and the deburred workpiece is ejected.
  • Fig. 2 shows a second embodiment of the device 1 according to the invention, the application unit 4 in this case having a movable nozzle head 21 with three outlet openings 10 in the form of a nozzle.
  • Different electrolyte jets can in turn be applied to the workpiece surface 2 to be processed via the outlet openings 10 as required.
  • the supply of the individual outlet opening 10 with the electrolyte, the control of the delivery unit 4 and the processing of the electrolyte sucked from the workpiece surface 2 are carried out using the same elements as were explained in connection with FIG. 1.
  • the delivery unit 4 shown in FIG a nozzle head 21, as indicated by arrows, can be moved relative to the workpiece 3.
  • the controlled movement of the outlet openings 10 and the discharge of the electrolyte takes place depending on the contour of the workpiece 3 fixed or clamped in its processing position, with the movement of the nozzle head 21, the supply of electrolyte to the individual outlet openings 10, the switching on and off Electrodes 6 arranged in the area of the outlet openings 10 and the setting of the voltage applied between an activated electrode 6 and the workpiece surface 2 to be machined are changed as required, in particular depending on the contour of a surface area to be machined, during machining.
  • the outlet openings 10 are in turn formed by pipe pieces and their open ends, with the individual electrically conductive pipe pieces taking on the function of electrodes 6, here as cathodes, which represent the counter electrodes to the anodic workpiece surface 2 during processing.
  • a voltage of 200 V to 450 V is applied between the activated pipe pieces and the workpiece surface 2 to be machined. Both during the ignition process at the start of workpiece machining and to initiate electrochemical machining steps, this voltage can be changed by changing a distance between the electrodes 6 arranged in the area of the outlet openings 10 and the workpiece surface 2 and/or targeted adjustment of the electrical energy source 7 serving as a voltage source.
  • the nozzle head 21 with its nozzle-shaped outlet openings 10 is then moved in such a way that the desired contour of the workpiece surface 2 is machined, here deburred.
  • the delivery unit 4 with its nozzle head 21 can be set up and positioned in such a way that the outer contour of the workpiece 3 to be processed is reproduced exactly or approximately.
  • the workpiece 3 is guided along the delivery unit 4 with the nozzle head 21 and its outlet openings 10. If individual surface areas of the workpiece 3 guided along the application unit 4 are not to be processed, it is possible to interrupt the application of electrolyte jets and/or the application of a voltage to this area, in particular via an adjusting means 12.
  • the application unit 4 forms a generic shape with the nozzle head 21 shown in FIG.
  • the application unit 4 with its movably arranged nozzle head 21 is moved and positioned by suitable drive elements, such as industrial robot arms, in order to successively move over the surface areas of the workpiece to be processed.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)

Abstract

L'invention concerne un dispositif (1) et un procédé de traitement électrolytique au plasma d'une surface électroconductrice (2) d'une pièce (3), selon lesquels il est essentiel qu'au moins deux zones d'action de jet soient générées sur la surface de la pièce. Le dispositif comporte une unité de distribution (4) pour appliquer sur la surface (2) un jet d'électrolyte, une unité d'alimentation (5) pour alimenter au moins temporairement l'unité de distribution (4) en électrolyte nécessaire à la formation d'un jet d'électrolyte, au moins une électrode (6) qui forme une contre-électrode par rapport à la surface (2) pendant le traitement, et au moins une source d'énergie électrique (7) permettant d'alimenter l'électrode et la surface en énergie électrique pendant le traitement de façon qu'un courant circule entre l'électrode (6) et la surface à traiter (2) au contact de l'électrolyte.
EP23744057.3A 2022-07-01 2023-06-30 Dispositif et procédé de traitement électrolytique au plasma de la surface électroconductrice d'une pièce au moyen de jets d'électrolyte Pending EP4359589A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP22182699.3A EP4299800A1 (fr) 2022-07-01 2022-07-01 Dispositif et procédé d'usinage électrolytique au plasma de la surface électriquement conductrice d'une pièce par jet d'électrolytes
PCT/EP2023/068123 WO2024003401A1 (fr) 2022-07-01 2023-06-30 Dispositif et procédé de traitement électrolytique au plasma de la surface électroconductrice d'une pièce au moyen de jets d'électrolyte

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EP4359589A1 true EP4359589A1 (fr) 2024-05-01

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EP22182699.3A Withdrawn EP4299800A1 (fr) 2022-07-01 2022-07-01 Dispositif et procédé d'usinage électrolytique au plasma de la surface électriquement conductrice d'une pièce par jet d'électrolytes
EP23744057.3A Pending EP4359589A1 (fr) 2022-07-01 2023-06-30 Dispositif et procédé de traitement électrolytique au plasma de la surface électroconductrice d'une pièce au moyen de jets d'électrolyte

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US (1) US20250121445A1 (fr)
EP (2) EP4299800A1 (fr)
JP (1) JP2025523318A (fr)
CN (1) CN117597475A (fr)
IL (1) IL309618A (fr)
WO (1) WO2024003401A1 (fr)

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Publication number Priority date Publication date Assignee Title
TW200949918A (en) * 2002-07-22 2009-12-01 Acm Res Inc Adaptive electropolishing using thickness measurements and removal of barrier and sacrificial layers
DE102006016368B4 (de) 2005-04-06 2013-12-19 Andreas Böhm Anlage und Verfahren zum Reinigen und Polieren der elektrisch leitfähigen Oberfläche eines Werkstückes sowie Verwendung des Verfahrens
DE102014108447B4 (de) 2014-06-16 2023-05-04 Plasotec Gmbh Anlage zum selektiven Plasmapolieren und/oder Reinigen der elektrisch leitenden Oberfläche von Bauteilen
RU2640213C1 (ru) * 2016-12-30 2017-12-27 Федеральное государственное автономное научное учреждение "Центральный научно-исследовательский и опытно-конструкторский институт робототехники и технической кибернетики" (ЦНИИ РТК) Способ струйного электролитно-плазменного полирования металлических изделий сложного профиля и устройство для его реализации
RU2681239C1 (ru) * 2018-06-13 2019-03-05 федеральное государственное автономное образовательное учреждение высшего образования "Санкт-Петербургский политехнический университет Петра Великого" (ФГАОУ ВО "СПбПУ") Устройство для электролитно - плазменной обработки металлических изделий
DE202019001138U1 (de) 2019-03-06 2019-03-28 Falko Böttger-Hiller Anlage zum Plasmapolieren durch Elektrolytstrahl
DE102019003597A1 (de) * 2019-05-17 2020-11-19 AMtopus GmbH & Co. KG Verfahren und Anlage zum Plasmapolieren
CN110125734B (zh) * 2019-06-11 2024-06-28 广东工业大学 一种机械臂辅助电解质等离子抛光装置及抛光方法

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US20250121445A1 (en) 2025-04-17
WO2024003401A1 (fr) 2024-01-04
IL309618A (en) 2024-02-01
CN117597475A (zh) 2024-02-23
EP4299800A1 (fr) 2024-01-03

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