Abstract:
A heterogeneous composite consisting of near-nano ceramic clusters dispersed within a ductile matrix. The composite is formed through the high temperature compaction of a starting powder consisting of a core of ceramic nanoparticles held together with metallic binder. This core is clad with a ductile metal such that when the final powder is consolidated, the ductile metal forms a tough, near-zero contiguity matrix. The material is consolidated using any means that will maintain its heterogeneous structure.
Abstract:
A method of producing at least one through-hole and countersink in at least one ultrahard insert including the steps of providing a body having a first major surface and an opposite second major surface; forming at least one pilot hole in said body using a laser, wherein said at least one pilot hole extends from said first major surface to the opposite second major surface of said body; cutting said pilot hole using a wire electrical discharge machine (WEDM) to produce a straight cylindrical portion and top conical portion; forming a countersink on at least one side of said body using an electrical discharge grinding machine (EDG); and severing said at least one ultrahard insert from said body forming a finished insert, wherein said finished insert includes a through-hole and a countersink.
Abstract:
Methods for fabricating a honeycomb extrusion die from a die body include the step of machining extrusion slots with at least one grinding wheel to provide a honeycomb pattern of extrusion slots. In further examples, a plurality of the extrusion slots of the honeycomb pattern of extrusion slots can be machined with a wire electrical discharge machining process after machining the plurality of extrusion slots of the honeycomb pattern of extrusion slots with the grinding wheel.
Abstract:
A method is provided for milling a thermal barrier coated metal part. This method includes selectively removing a portion of a ceramic coating using a mechanical cutting tool, thereby forming a counterbore, and machining the metal part through the counterbore. A drilling head for drilling thermal barrier coated metal parts is also provided. The drilling head comprises a mechanical cutting tool, which is operable to mill through ceramic, and an electrode for electrical discharge machining. The electrode may be used to mill the metal part, and may be interchangeable with the mechanical cutting tool.
Abstract:
The present invention relates to an apparatus for machining holes, especially to machine holes in a surface of a coated gas turbine airfoil, which apparatus comprises a laser device for laser drilling and an electrode for electrical discharge machining. Further the invention relates to a method to machine a hole into a coated surface with an apparatus of the incipiently mentioned type. Known methods make use of a machine with separate machine heads for laser drilling and electrical discharge machining. By combining these two devices in one machine head the invention gives the possibility to save time and obtain very accurate results.
Abstract:
An apparatus and method for hybrid machining a workpiece is disclosed. The apparatus includes a mandrel for supporting the workpiece adjacent a cutter mounted on an arbor. A workpiece is powered as an anode and the cutter is powered as a cathode, and a cutting fluid or coolant is circulated therebetween. The cutter is made of a conductive material and a non-conductive abrasive material to maximize the amount of material removed from the workpiece. The coolant includes one or more additives to enhance the electrical discharge between the cutter and the workpiece. The cutter is moved relative to the workpiece to remove material from the workpiece at a predetermined depth of cut using an enhanced high-speed electro-erosion (HSEE) process in which both HSEE and abrasive machining processes are used. The workpiece may then be finish machined to a final shape of the titanium article, such as a dovetail of a turbine blade.
Abstract:
The invention relates to a method and a device for the electroerosive dressing of grinding wheels having an electrically conductive bond. The dressing tool comprises a cylindrical electrode pair divided into two, the electrodes (2, 3) of which have a different polarity and are separated from one another by insulation (4). A voltage circuit is directed via the two electrodes (2, 3). The voltage may either be a direct-current voltage of an alternating-current voltage. The dressing tool rotates and is pressed against the grinding wheel (1) with a constant force. The two dressing electrodes (2, 3) are supplied with current from a generator (7) via brushes (5,6) in such a way that it flows through the electrode (3) into the grinding wheel (1and from the latter back into the other electrode (2). The commutator-like arrangement of the two electrodes (2,3) and the brushes (5, 6) causes upon rotation a periodic alternation in the plurality of the applied voltage, which permits more uniform dressing in a simple and effective way.
Abstract:
A machining tool is provided with an electric discharge truing/dressing apparatus comprising a spindle stock for containing and supporting a workpiece spindle which is driven for rotation while holding a workpiece or an electrode; a tool rest which moves parallel and perpendicular to the spindle of the spindle stock and holds an electrode machining tool and a grinding wheel; a feed electricity means disposed between a workpiece supporting portion of the spindle and the tool rest; a magazine disposed at an outside area of a machining area of the tool rest and adapted to store the workpiece and the electrode; and a loading device disposed between the magazine and the spindle. The grinding wheel on the tool rest is subjected to truing/dressing by feeding the electrode from the magazine to the spindle stock.
Abstract:
This invention relates to a composite processing machine designed so as to be movable in a longitudinal and lateral direction on the side of a work table so that cutting process, discharge process, electrolytic grinding process and the like may be accomplished by a single machine, comprising means for moving a work table (1) on a machine bed (2) in a direction of x-axis and y-axis, a processing unit (9) having a chuck (14) capable of being detachably engaged with various tools and a discharge electrode at the fore end of a spindle (1) positioned upwardly of the work table (1) and comprising a motor (15) for rotating spindle and a fixing brake (12), means for moving a processing unit (9) in a direction of z-axis, an auto tool changer (18) for holding a cutting tool, a discharge electrode, a measuring probe, a grinding wheel and the like to selectively feed them to the chuck, and a processing power source (22) connected over a discharge electrode (26) or a grinding wheel (51) mounted on the chuck (14) and a work (4) within the liquid tank or a nozzle (50) for coolent to apply a dc current to a processing power source (22).
Abstract:
A heterogeneous composite consisting of near-nano ceramic clusters dispersed within a ductile matrix. The composite is formed through the high temperature compaction of a starting powder consisting of a core of ceramic nanoparticles held together with metallic binder. This core is clad with a ductile metal such that when the final powder is consolidated, the ductile metal forms a tough, near-zero contiguity matrix. The material is consolidated using any means that will maintain its heterogeneous structure.