ELECTROCHEMICAL MACHINING APPARATUS

Abstract

An electrochemical machining apparatus includes a support assembly, a machining electrode assembly, a tank configured to hold an electrolyte, a workpiece holder positioned in the tank, a movable feed assembly, and a connecting member. The machining electrode assembly includes a first machining electrode and a second machining electrode. The movable feed assembly includes a first feed subassembly and a second feed subassembly. The connecting member is connected to the first feed subassembly and the second feed subassembly. The first machining electrode is coupled with the connecting member, and the second machining electrode is coupled with the second feed subassembly. The second feed subassembly can move with, and relative to, the first feed subassembly. The second machining electrode can slide in the first machining electrode.

Description

FIELD

The subject matter herein generally relates to an electrochemical machining apparatus.

BACKGROUND

Electrochemical machining (ECM) is a commonly used method of machining electrically conductive workpieces with one or more electrically conductive tools. During processing, a tool electrode is located relative to the workpiece, such that there is a gap between the tool electrode and the workpiece. The gap is filled with a pressurized aqueous electrolyte, such as an aqueous sodium nitrate solution. A direct current electrical potential is established between the tool electrode and the workpiece to cause controlled depletion of the electrically conductive workpiece. The depletion action takes place in an electrolytic cell formed by the negatively charged electrode (cathode) and the positively charged workpiece (anode) separated by the flowing electrolyte. The depleted material is removed from the gap by the flowing electrolyte, which also removes heat formed by the chemical reaction. The anodic workpiece generally assumes a contour that matches that of the cathode tool.

BRIEF DESCRIPTION OF THE DRAWINGS

Implementations of the present technology will now be described, by way of example only, with reference to the attached figures.

FIG. 1 is a diagrammatic view of an electrochemical machining apparatus according to an embodiment.

FIG. 2 is an exploded, isometric view of a machining electrode assembly in the electrochemical machining apparatus shown in FIG. 1.

FIG. 3 is an assembled, isometric view of the machining electrode assembly as shown in FIG. 2.

FIG. 4 is an isometric view of the machining electrode assembly and the movable feed assembly as shown in FIG. 1.

FIG. 5 is a diagrammatic view of the electrochemical machining apparatus in machining process housing.

FIG. 6 is a diagrammatic view of the electrochemical machining apparatus in a machining process in the housing through a hole.

DETAILED DESCRIPTION

It will be appreciated that for simplicity and clarity of illustration, where appropriate, reference numerals have been repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures, and components have not been described in detail so as not to obscure the related relevant feature being described. Also, the description is not to be considered as limiting the scope of the embodiments described herein. The drawings are not necessarily to scale and the proportions of certain parts have been exaggerated to better illustrate details and features of the present disclosure.

Several definitions that apply throughout this disclosure will now be presented.

The term “coupled” is defined as connected, whether directly or indirectly through intervening components, and is not necessarily limited to physical connections. The connection can be such that the objects are permanently connected or releasably connected. The term “substantially” is defined to be essentially conforming to the particular dimension, shape, or other feature that the term modifies, such that the component need not be exact. For example, substantially cylindrical means that the object resembles a cylinder, but can have one or more deviations from a true cylinder. The term “comprising” when utilized, means “including, but not necessarily limited to”; it specifically indicates open-ended inclusion or membership in the so-described combination, group, series and the like.

The present disclosure is in relation to an electrochemical machining method and apparatus for a metal housing with a through hole therein. The metal housing can be a housing of an electronic product, such as a mobile phone. The through hole can be a sound hole, a headphone jack, a trademark, or other hole.

FIG. 1 illustrates that the electrochemical machining apparatus 100 can include a machining electrode assembly 10, a support assembly 20, a movable feed assembly 30, an XY axis driving assembly 40, a tank 50 configured to hold an electrolyte, a workpiece holder 60, a connecting member 70, and a feed controller 80.

The support assembly 20 can include a bracket 21 and a base 22, and the bracket 21 can be mounted substantially perpendicular on the base 22. The base 22 can include a support plane 221.

The movable feed assembly 30 can move in an axis substantially perpendicular to the support plane 221, and can include a first feed subassembly 31 and a second feed subassembly 32. The first feed subassembly 31 can be mounted on the bracket 21 of the support assembly 20, and the second feed subassembly 32 can be mounted on the connecting member 70.

The XY axis driving assembly 40 can be positioned on the base 22, and can move in a plane substantially parallel with the support plane 221. The tank 50 can be mounted on the XY driving assembly 40, and the workpiece holder 60 can be positioned in the tank 50. The workpiece holder 60 can be used to fix a workpiece 90. The tank 50 can be moved with the XY axis driving assembly 40, and the workpiece 90 can be moved simultaneously.

The connecting member 70 can be L shaped and can connect the first feed subassembly 31 and the second feed subassembly 32. The second feed subassembly 32 can be positioned above the connecting member, and the machining electrode assembly 10 can be positioned below the connecting member.

As the connecting member 70 can be connected to the movable feed assembly 30, and the machining electrode assembly 10 can be connected to the connecting member 70, the movable feed assembly 30 can drive the machining electrode assembly 10 to move. The feed controller 80 can be used to control the movement of the movable feed assembly 30.

FIG. 2 illustrates that the machining electrode assembly 10 can include a first machining electrode 11 and a second machining electrode 12. A shape of the first machining electrode 11 can be matched with a shape of the metal housing. In at least one embodiment, the first machining electrode 11 can be substantially rectangular and include a hollow portion 112. A shape of the hollow portion 112 can be substantially the same as the through hole of the metal housing, and the hollow portion 112 can be arranged to correspond to the through hole in the metal housing. The first machining electrode 11 can further include a first machining surface 111.

The second machining electrode 12 can include a bottom portion (not labeled) and a protrusion portion (not labeled) protruding out of the bottom portion. The protrusion portion can have a shape matching that of the hollow portion 112. The protrusion portion of the second machining electrode 12 can include a second machining surface 121. A shape of the second machining surface 121 can be substantially that of a shape of the hollow portion 112. In at least one embodiment, the hollow portion 112 and the protrusion portion of the second machining electrode 12 can be triple prism shaped. In other embodiments, the hollow portion 112 and the protrusion portion of the second machining electrode 12 can have other shapes as long as the shape is substantially same as that of the through hole in the metal housing.

FIG. 3 illustrates that the second machining electrode 12 can be partially positioned in the hollow portion 112 and slidable into the first machining electrode 11. The first machining surface 111 and the second machining surface 121 can cooperatively form a cavity machining surface 113 when the first machining surface 111 is coplanar with the second machining surface 121.

FIG. 4 illustrates that the connecting member 70 can be L shaped and can include a vertical part 71 and a horizontal part 72. The horizontal part 72 can define a via hole 73 in the central portion thereof. The via hole 73 can be substantially circular, rectangular, or other shape.

The vertical part 71 can be connected to the horizontal part 72. The second feed subassembly 32 can include an output shaft 321. The second feed subassembly 32 can be mounted above the horizontal part 72, and the output shaft 321 can pass through the via hole 73 and extend vertically to the horizontal part 72. As the connecting member 70 can connect the first feed subassembly 31 and the second feed subassembly 32, the first feed subassembly 31 can drive the second feed subassembly 32 to move. Furthermore, the feed controller 80 can drive the first feed subassembly 31 and/or the second feed subassembly 32 to move along a direction perpendicular to the base 22. As a result, the second feed subassembly 32 can move with, and relative to, the first feed subassembly 31. The first feed subassembly 31 and the second feed subassembly 32 can be a combination of stepped motor and ball-screw, or a voice coil motor linear actuator. In other embodiments, the first feed subassembly 31 and the second feed subassembly 32 can be other linear motion mechanisms with high precision.

The first machining electrode 11 can be connected to the horizontal portion 72 by a plurality of screw bolts 74, and the output shaft 321 can be positioned to correspond to the hollow portion 112 of the first machining electrode 11. The first machining surface 111 can be substantially parallel to the horizontal part 72 of the connecting member 70.

One end of the second machining electrode 12 can be connected to the output shaft 321 of the second feed subassembly 32, and the other end can slide in the hollow portion 112 of the first machining electrode 11.

As the second feed subassembly 32 can move relative to the first subassembly 31, the second machining electrode 12 coupled to the second feed subassembly 32 can move relative to the first machining electrode 11 coupled with the first subassembly 31. When the first machining surface 111 is coplanar with the second machining surface 121, the cavity machining surface 113 can be used to form the housing of the workpiece 90. When the second machining surface 121 is protruding out of the first machining surface 111, the second machining surface 121 can be used to form the through hole of the workpiece 90.

FIG. 5 illustrates the electrochemical machining process applied to the metal housing. The electrochemical machining method can include the steps as follows. Firstly, the workpiece 90 can be fixed to the workpiece holder 60, and the XY axis driving assembly 40 can be moved, whereby the workpiece 90 can be positioned directly facing the machining electrode 10.

The second feed subassembly 32 can be moved, and the second machining electrode 12 can be moved relative to the first machining electrode 11, thereby the second machining surface 112 can be made coplanar with the first machining surface 111 to form the cavity machining surface 113. Then, the first feed subassembly 31 can be moved to adjust the machining gap between the workpiece 90 and the machining electrode assembly 10, and the workpiece 90 is machined to be a cavity for use as a housing.

After that, the first feed subassembly 31 can be moved upward, and the machining electrode 10 can be lifted to the initial position.

Then, the second feed subassembly 32 can be moved downward, whereby the second machining electrode 12 can protrude out of the first machining electrode 11.

The first feed subassembly 31 can be moved downward, and the workpiece 90 can be machined by the second machining electrode 12 to form the through hole in the housing.

After the through hole is made, the first feed subassembly 31 can be moved upward, and the machining electrode assembly 10 can be lifted. Then, the workpiece 90 can be removed from the workpiece holder 60. The workpiece 90 can be the housing with the through hole therein.

As the machining electrode assembly 10 includes a first machining electrode 11 and a second machining electrode 12, the electrochemical machining apparatus 100 can be used continuously to form the housing and the through hole, and there is no need to replace the machining electrode. The machining method can reduce manufacturing cost and improve machining efficiency.

The embodiments shown and described above are only examples. Many details are often found in the art such as the other features of an electrochemical machining apparatus. Therefore, many such details are neither shown nor described. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only, and changes may be made in the detail, especially in matters of shape, size, and arrangement of the parts within the principles of the present disclosure, up to and including the full extent established by the broad general meaning of the terms used in the claims. It will therefore be appreciated that the embodiments described above may be modified within the scope of the claims.

Claims

1. An electrochemical machining apparatus comprising:

a support assembly having a support plane;

a machining electrode assembly having a first machining electrode and a second machining electrode;

a tank positioned on the support plane of the support assembly;

a workpiece holder positionable within the tank; and

a movable feed assembly having a first feed subassembly and a second feed subassembly with an output shaft; and

a connecting member connecting the first feed subassembly and the second feed subassembly;

wherein, the movable feed assembly is movable in an axis substantially perpendicular to the support plane of the support assembly;

wherein, the first machining electrode is connected to the connecting member and the second machining electrode is connected to the second feed subassembly output shaft;

wherein, the second feed subassembly is movable with, and relative to, the first feed subassembly; and

wherein, the second machining electrode is slidable into the first machining electrode.

2. The electrochemical machining apparatus of claim 1, wherein the first machining electrode defines a hollow portion, and the second machining electrode is slidable in the hollow portion.

3. The electrochemical machining apparatus of claim 2, wherein the first machining electrode includes a first machining surface, and the second machining electrode includes a second machining surface; a shape of the second machining surface is substantially the same as the hollow portion.

4. The electrochemical machining apparatus of claim 3, wherein the first machining surface is coplanar with the second machining surface to form a cavity machining surface.

5. The electrochemical machining apparatus of claim 3, wherein the second machining surface protrudes out of the first machining surface.

6. The electrochemical machining apparatus of claim 3, wherein the first machining electrode is substantially rectangular.

7. The electrochemical machining apparatus of claim 1, wherein the electrochemical machining apparatus further comprises an XY axis driving assembly mounted on the support assembly; the XY axis driving assembly is movable in a plane substantially parallel with the support plane, and the tank is mounted on the XY axis driving assembly.

8. The electrochemical machining apparatus of claim 1, wherein the electrochemical machining apparatus further comprises a feed controller used to drive the first feed subassembly and the second subassembly.

9. The electrochemical machining apparatus of claim 1, wherein the connecting member comprises a vertical part and a horizontal part, and the horizontal part defines a via hole.

10. The electrochemical machining apparatus of claim 9, wherein the second feed subassembly is mounted on the horizontal part and partially passes through the via hole.

11. The electrochemical machining apparatus of claim 1, wherein the support subassembly includes a bracket and a base; the bracket is substantially perpendicular to the base, and the first feed subassembly is coupled to the bracket.