Method for producing a metal component

Abstract

Method for machining a metal component which has a three-dimensional shape produced by removing and/or shaping material, wherein one or more superior component sections are electrochemically finish-machined by means of a nozzle-like cathode, via which an electrolyte is delivered into the working region, and wherein the cathode or the metal component is moved freely in space by means of a manipulator element.

1 . A method for machining a metal component which has a three-dimensional shape produced by removing and/or shaping material, the method comprising the steps of: electrochemically machining at least one superior component section using a nozzle-like cathode, via which an electrolyte is delivered into a working region; and moving the cathode or the metal component freely in space with a manipulator element. 
     
     
         2 . The method according to  claim 1 , wherein the manipulator element is a robot having a plurality of motion axes. 
     
     
         3 . The method according to  claim 2 , wherein the robot has five or six motion axes. 
     
     
         4 . The method according to  claim 1 , including also moving the metal component arranged on a movable work holder in the case of the cathode being moved by the manipulator element during machining. 
     
     
         5 . The method according to  claim 1 , including also moving the cathode arranged on a movable holder in the case of the metal component being moved by the manipulator element during machining. 
     
     
         6 . The method according to  claim 1 , including delivering the electrolyte as a stream of substantially round cross section from a cathode having a corresponding cross-sectional geometry. 
     
     
         7 . The method according to  claim 1 , wherein a working voltage applied between the cathode and the metal component or a process current flowing therebetween is constant or pulsed and/or a volumetric flow of the electrolyte is between 10 and 100 l/h. 
     
     
         8 . The method according to  claim 7 , including determining a distance of the cathode from a surface of the metal component from a ratio of working voltage and process current and/or, as a function thereof, and controlling a process sequence by varying any desired process parameter. 
     
     
         9 . The method according to  claim 6 , including blowing out a gas curtain laterally enclosing the electrolyte stream at least partly via the cathode. 
     
     
         10 . The method according to  claim 1 , wherein the metal component to be machined consists of a metallic or intermetallic material. 
     
     
         11 . The method according to  claim 10 , wherein the metal component is a steel, a titanium alloy or a nickel alloy. 
     
     
         12 . The method according to  claim 1 , wherein the metal component is a component of a turbomachine. 
     
     
         13 . The method according to  claim 12 , wherein the component of a turbomachine is a blade component, in particular a guide vane cluster or a guide vane ring. 
     
     
         14 . The method according to  claim 13 , wherein the superior component sections machined are edges and surfaces in a region between two airfoils of the blade component and/or the airfoils of the blade component themselves. 
     
     
         15 . An apparatus for implementing the method according to  claim 1 , comprising: a manipulator element formed as a multi-axis robot; an ECM tool formed as a nozzle-like cathode or a work holder arranged on the manipulator; an electrolyte feed device for feeding electrolyte from an electrolyte reservoir to the cathode; a process energy source connected to the cathode and the metal component; and a control device controlling operation of the apparatus. 
     
     
         16 . The apparatus according to  claim 15 , wherein the cathode has a round cross section. 
     
     
         17 . The apparatus according to  claim 15 , wherein the cathode is designed for delivering gas, fed to the cathode via a gas feed device, formed as a gas curtain laterally enclosing the electrolyte stream at least partly, said electrolyte stream discharging from the cathode. 
     
     
         18 . The apparatus according to  claim 15 , wherein the work holder is additionally movable when the cathode is arranged on the manipulator element, or the cathode is additionally movable when the work holder is arranged on the manipulator element. 
     
     
         19 . The apparatus according to  claim 15 , further comprising means for detecting a distance of the cathode from a surface of the component. 
     
     
         20 . The apparatus according to  claim 19 , wherein the means is the control device, which determines the distance with reference to a ratio of working voltage and process current and, as a function thereof, controls a process sequence by varying any desired process parameter. 
     
     
         21 . The apparatus according to  claim 19 , wherein the means is a sensor, wherein the control device controls a process sequence by varying any desired process parameter as a function of a detection result of the sensor.