Patent ID: 12226810

DETAILED DESCRIPTION

In the following description, certain specific details are set forth to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with high pressure waterjet systems have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments.

Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense that is as “including, but not limited to.”

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. For example, certain features of the disclosure which are described herein in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features of the disclosure that are described in the context of a single embodiment may also be provided separately or in any subcombination.

As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its broadest sense, that is as meaning “and/or” unless the content clearly dictates otherwise. Reference herein to two elements “facing” or “facing toward” each other indicates that a straight line can be drawn from one of the elements to the other of the elements without contacting an intervening solid structure.

The term “aligned” as used herein in reference to two elements along a direction means a straight line that passes through one of the elements and that is parallel to the direction will also pass through the other of the two elements. The term “between” as used herein in reference to a first element being between a second element and a third element with respect to a direction means that the first element is closer to the second element as measured along the direction than the third element is to the second element as measured along the direction. The term “between” includes, but does not require that the first, second, and third elements be aligned along the direction.

Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range including the stated ends of the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.

Aspects of the disclosure will now be described in detail with reference to the drawings, wherein like reference numbers refer to like elements throughout, unless specified otherwise. Certain terminology is used in the following description for convenience only and is not limiting. The term “plurality”, as used herein, means more than one. The terms “a portion” and “at least a portion” of a structure include the entirety of the structure. The term “cutting through” a structure refers to a complete removal of material through an entire thickness of the structure along the direction of impact of the cutting apparatus, for example the direction of travel of a waterjet just before it strikes a surface of the workpiece.

The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.

Referring toFIG.1, a system10can be used to perform a finishing operation (also referred to herein as “finishing”) on an article12. The article12can be a manufactured part, for example one produced by an additive manufacturing process, such as3D printing. The system10, according to one embodiment, is capable of performing one or more finishing operations on one or more of the articles12, simultaneously. The one or more articles12can include a plurality of identical articles, or can include a plurality of different articles.

As shown in the illustrated embodiment, the system10can include a receptacle14, for example a water tank, that at least partially encloses a fluid16of the system10. For example, the receptacle14can include a base and side-walls and have an open top. According to another embodiment, the top of the receptacle14can be at least partially enclosed as well. As shown, the receptacle14can be supported by a surface15, for example a floor.

The fluid16can be a pure fluid, for example water, devoid of any particulate material, such as an abrasive, prior to operation of the system10. Alternatively, the fluid16can be a slurry that includes a mixture of a liquid, for example water, and an abrasive17.

The system10can further include a tubular member18positioned within the receptacle14such that the tubular member18is at least partially submerged within the fluid16. As shown, the tubular member18can define an interior space20, an entry opening22providing access for the fluid into the interior space20, and an exit opening24providing access from the interior space20.

The system10can include a waterjet assembly26that outputs a high velocity jet28. The high velocity jet28can be a pure water jet, such that the jet is devoid of abrasives added prior to the jet being output from the waterjet assembly26. According to one embodiment the high velocity jet28can be an abrasive jet, including a fluid, for example water, laden with abrasive material such as the abrasive17, prior to output from the waterjet assembly26. The high velocity jet28can be output at a pressure of at least 90,000 psi. According to another embodiment, the high velocity jet28can be output at a pressure of at least 40,000 psi. According to another embodiment, the high velocity jet28can be output at a pressure of at least 20,000 psi.

As shown in the illustrated embodiment, the waterjet assembly26can be positioned such that the high velocity jet28is output along a path30that passes through at least a portion of the interior space20and then exits through the exit opening24. According to one embodiment, the path30is parallel to the surface15. According to another embodiment, the path30is non-parallel, for example perpendicular to the surface15.

The entry opening22can be positioned relative to the exit opening24such that as the high velocity jet28passes through at least a portion of the interior space20and then exits through the exit opening24, a portion of the fluid16is drawn through the entry opening22(as shown by the arrow) and into the interior space20. As shown, the entry opening22can be angularly offset, for example perpendicular, to the exit opening24. According to one embodiment, the entry opening22can be angularly parallel to the exit opening24.

The abrasive17, whether part of the fluid16in the receptacle14, or part of the high velocity jet28, can have round edges, sharp edges, or can be a mixture that includes some particles with round edges and some particles with sharp edges. The abrasive17can include particles with a size of 80 mesh, 120 mesh, 240 mesh, 400 mesh, or any combination thereof. The abrasive17can include garnet, aluminum oxide, silicon carbide, steel grit, glass beads, or any combination thereof.

According to one embodiment, the system10can include multiple types (for example different size, shape, or material) of the abrasive17. The system10can include a controller to facilitate substitution of one type of the abrasive17for another type of the abrasive17. For example, the system10may include a first abrasive17configured for use in a first finishing operation, such as powder removal, and further include a second abrasive17configured for use in a second finishing operation, such as peening.

The system10can include a support structure32positioned to support the article12within the receptacle14such that the article12is at least partially submerged in the fluid16. According to one embodiment, the support structure32is positioned to support the article12such that the path30intersects a surface of the article12. The support structure32can be movable such that an angle at which the path30intersects the surface of the article12is adjustable. According to one embodiment, the angle is adjustable between 0 degrees and 90 degrees. According to one embodiment, the angle is adjustable between 0 degrees and 180 degrees.

The support structure32can be movable such that the support structure32is able to manipulate, for example translate, rotate, or both, the article12such that the path30intersects a first surface of the article12when the support structure32is in a first orientation and intersects a second surface of the article12when the support structure32is in a second orientation. According to one embodiment, in the second configuration the path30does not intersect the first surface of the article12.

The support structure32can be movable such that the article12, while supported by the support structure32, is movable in up to six degrees of freedom. As shown in the illustrated embodiment, the support structure32can include a robotic arm.

The system10can include a plurality of waterjet assemblies. For example, the system10can include a second waterjet assembly (not shown) that outputs a second high velocity jet of water. The second waterjet assembly can be positioned such that the second high velocity jet of water is output along a second path that passes through the fluid16. The second waterjet assembly can be positioned such that the second path is collinear with the first path. According to one embodiment the second waterjet assembly can be positioned such that the second path is parallel and offset with respect to the first path. According to one embodiment the second waterjet assembly can be positioned such that the second path is perpendicular to the first path. The system10can include a plurality of the tubular members18, for example one of the tubular members18for each of the waterjet assemblies26of the system10.

The system10can include a controller34capable of changing one or more settings of the system10. The one or more settings can include, for example, velocity of the high velocity jet28, pressure of the high velocity jet28, position of the article12relative to the path30, and angle at which the path30intersects the article12. The controller34can include a plurality of configurations that each correlate to a specific value, for example a range of values, for each of one or more settings.

According to one embodiment, the system10can include an input assembly36that allows an end user to select one of the plurality of configurations to be the active configuration, thereby changing the specific value for each of the one or more settings to the respective values that correlate to the selected one of the plurality of configurations. For example, the input assembly36may include a first input that correlates to a powder removal finishing operation, and upon actuation of the first input the controller34adjusts the one or more settings, for example velocity of the high velocity jet28, to correlate to the specific value for the powder removal finishing operation.

It will be understood by those skilled in the art that the changing of the one or more settings of the system10can be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof. In one embodiment, the present subject matter may be implemented via Application Specific Integrated Circuits (ASICs). However, those skilled in the art will recognize that the embodiments disclosed herein, in whole or in part, can be equivalently implemented in standard integrated circuits, as one or more computer programs executed by one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs executed by on one or more controllers (e.g., microcontrollers) as one or more programs executed by one or more processors (e.g., microprocessors), as firmware, or as virtually any combination thereof, and that designing the circuitry and/or writing the code for the software and or firmware would be well within the skill of one of ordinary skill in the art in light of the teachings of this disclosure.

When logic is implemented as software and stored in memory, logic or information can be stored on any computer-readable medium for use by or in connection with any processor-related system or method. In the context of this disclosure, a memory is a computer-readable medium that is an electronic, magnetic, optical, or other physical device or means that contains or stores a computer and/or processor program. Logic and/or the information can be embodied in any computer-readable medium for use by or in connection with an instruction execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that can fetch the instructions from the instruction execution system, apparatus, or device and execute the instructions associated with logic and/or information.

In the context of this specification, a “computer-readable medium” can be any element that can store the program associated with logic and/or information for use by or in connection with the instruction execution system, apparatus, and/or device. The computer-readable medium can be, for example, but is not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus or device. More specific examples (a non-exhaustive list) of the computer readable medium would include the following: a portable computer diskette (magnetic, compact flash card, secure digital, or the like), a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM, EEPROM, or Flash memory), a portable compact disc read-only memory (CDROM), digital tape, and other nontransitory media.

According to one embodiment, the controller34includes at least one computer readable medium storing logic or information for the changing of the one or more settings of the system10as described herein.

Referring toFIG.2, an embodiment of the system10can be similar to the system10as described inFIG.1, and can include any combination of the elements shown and described above in reference toFIG.1. As shown, the system10can be devoid avoid the tubular member18. The system10can include the waterjet assembly26which outputs the high velocity jet28laden with the abrasive17. The system10can include an abrasive removal assembly38that removes the abrasive17from the receptacle14. The abrasive removal assembly38can include a vacuum source or pump, and can recycle the abrasive17for re-use in a future finishing operation by the system10.

Referring toFIGS.1and2, a method of finishing the article12includes submerging a portion of the article12, for example the entirety of the article12, in the fluid16within the receptacle14. The method can further include producing the high velocity jet28, for example a high velocity jet of water produced by the waterjet assembly26, and outputting the high velocity jet28along the path30, which intersects the portion of the article12submerged in the fluid16. The method can further include impacting the portion of the article12with a slurry thereby altering a characteristic of the portion of the article12without cutting through the portion of the article12. For example, the slurry can dent, deform, erode, polish, etc., but does not cut completely through the thickness of the article12along the direction of impact of the slurry. The slurry can include the high velocity jet28and the abrasive17.

The method can include positioning the waterjet assembly26such that a nozzle of the waterjet assembly26that outputs the high velocity jet28is submerged in the fluid16.

As shown inFIG.1, the method can include directing the high velocity jet28along the path30such that the high velocity jet28passes through at least a portion of the interior space20defined by the tubular member18submerged in the fluid16, and then exits through the exit opening24defined by the tubular member18prior to impacting the portion of the article12. The method can include drawing a portion of the fluid16through the entry opening22of the tubular member18, and drawing the portion of the fluid16into the interior space20. According to one embodiment, the fluid is drawn through the entry opening22as a result of movement of the high velocity jet28through the interior space20.

Referring toFIG.3, an embodiment of the system10can be similar to the system10as described inFIG.1andFIG.2, and can include any combination of the elements shown and described above in reference toFIG.1andFIG.2. As shown in the illustrated embodiment, the system10can include the receptacle14at least partially enclosing the fluid16. The receptacle14can define a circular shape, as shown. The system10can include at least one of the waterjet assembly26that outputs the high velocity jet28along the path30, which is submerged within the fluid16. The at least one waterjet assembly26can be positioned such that, upon activation, the high velocity jet28forms a current48in the fluid16that rotates about an axis of rotation50. As shown in the illustrated embodiment, the current48can be clockwise as viewed from above the receptacle14.

The at least one waterjet assembly26can include a plurality of waterjet assemblies, for example first and second waterjet assemblies. Each of the plurality of waterjet assemblies outputs a respective high velocity jet28, for example a high velocity jet of water, along a respective path30. As shown, each of the respective paths30can be offset from one another. For example, the respective paths30can be coplanar and non-collinear. According to one embodiment, the respective paths30can be coplanar and non-parallel. According to one embodiment, the respective paths30can be defined within different planes, such that they are not coplanar. The plurality of waterjet assemblies can further include a third waterjet assembly. The plurality of waterjet assemblies can include additional waterjet assemblies.

The system10can include the support structure32positioned to support the article12within the receptacle14such that the article12is at least partially submerged in the fluid16. As shown, the support structure32can position the article12such that the article12intersects the axis of rotation50. According to one embodiment the support structure32can position the article12such that at least one of the respective paths30, for example all of the respective paths30, does not intersect the article12. According to one embodiment the support structure32can position the article12such that at least one of the respective paths30, for example all of the respective paths30, intersects the article12.

According to one embodiment, the system10current48defines zones52of different strengths within the fluid16. The zones52of different strengths52can be based on speed of the current48within the respective zone52, density of the abrasive17within the respective zone52, or both.

The support structure32can be positioned to support the article12within the receptacle14such that the article12is movable between different ones of the zones52of different strengths. The zones52of different strengths can be arranged as concentric rings, for example, centered on the axis of rotation52as shown in the illustrated embodiment. The zones52of different strengths can include a first zone52aand a second zone52b, the first zone52apositioned closer to the axis of rotation50than the second zone52bis from the axis of rotation50. According to one embodiment, the first zone52acan include at least one of a faster current and a more concentrated amount of the abrasive17.

A method of finishing the article12can include submerging a portion of the article12in the fluid16, forming the current48in the fluid16, for example such that the current48rotates about the axis of rotation50, and impacting a surface of the article12with the abrasive17. Impacting the surface of the article12includes altering a characteristic of the surface of the article12without cutting through the portion of the article12. The abrasive17can be moved relative to the article12by the current48.

Forming the current48can include producing the high velocity jet28submerged within the fluid16, and directing the high velocity jet28along the path30. As shown, the path30may not intersect the axis of rotation50. Forming the current48can include producing a second high velocity jet28that is also submerged within the fluid16. The method can further include directing the second high velocity jet28along a second path30that does not intersect the axis of rotation50and that is offset from the first path30. The method can further include moving the article12from one of the zones52of different strengths, for example the first zone52a, to another of the zones52of different strengths, for example the second zone52b.

The above description of illustrated embodiments, including what is described in the Abstract, is not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. Although specific embodiments of and examples are described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the disclosure, as will be recognized by those skilled in the relevant art. The various embodiments described above can be combined to provide further embodiments.

Many of the methods described herein can be performed with variations. For example, many of the methods may include additional acts, omit some acts, and/or perform acts in a different order than as illustrated or described.

These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.