Electrical discharge machining method for generating variable spray-hole geometry
A method is provided comprising identifying an alignment point of a workpiece; positioning a first end of an electrode in the direction of the alignment point of the workpiece; applying a first voltage to the electrode wherein the applied first voltage generates a spark; rotating the electrode in a first direction; advancing the electrode toward the alignment point by a first distance wherein advancing the electrode and applying the first voltage creates a first orifice section; applying a second voltage to the electrode and modifying one or more operational parameters of the electrode; advancing the electrode toward the alignment point by a second distance wherein advancing the electrode and applying the second voltage causes formation of at least a second orifice section; wherein the first and second orifice sections cooperate to form an orifice comprising a first flow area and a second flow area.
1. A method of operating an electrical discharge machining (EDM) system including an electrode electronically controllable to form an orifice in a workpiece, the method comprising:
positioning a first end of an electrode in a direction of an alignment point located along a longitudinal axis intersecting the workpiece;
creating a first orifice section in the workpiece including applying a voltage to the electrode effective to generate a spark, rotating the electrode at an angle relative to the longitudinal axis, and moving the electrode relative to the alignment point by a first distance; and
after creating the first orifice section, creating a second orifice section in the workpiece including adjusting the voltage applied to the electrode, adjusting the angle of rotation of the electrode relative to the longitudinal axis, and moving the electrode relative to the alignment point by a second distance;
wherein a first flow area of the first orifice section is greater than a second flow area of the first orifice section.
2. The method of claim 1 , comprising:
after creating the second orifice section, creating a third orifice section in the workpiece including second adjusting the voltage applied to the electrode, second adjusting the angle of rotation of the electrode relative to the longitudinal axis, and moving the electrode relative to the alignment point by a third distance; and
after creating the third orifice section, creating a fourth orifice section in the workpiece including third adjusting the voltage applied to the electrode, third adjusting the angle of rotation of the electrode relative to the longitudinal axis, and moving the electrode relative to the alignment point by a fourth distance.
3. The method of claim 2 , wherein the first orifice section, the second orifice section, the third orifice section, and the fourth orifice section comprise portions of a venturi shape.
4. The method of claim 2 , wherein the first orifice section and the second orifice section comprise at least a portion of an outlet section of the orifice, the third orifice section comprises at least a portion of a middle section of the orifice, and the fourth orifice section comprises at least a portion of an inlet section of the orifice.
5. The method of claim 4 , wherein a diameter of the outlet section of the orifice has a diameter greater than a diameter of the middle section of the orifice, and a diameter of the inlet section of the orifice has a diameter that is greater than the diameter of the middle portion of the orifice.
6. The method of claim 1 , wherein the workpiece comprises at least a first portion of a fuel injector nozzle and the orifice is an injection orifice of the fuel injector nozzle.
7. The method of claim 1 , comprising: identifying the alignment point of the workpiece, the alignment point being located along a central longitudinal axis of the workpiece.
8. A system for electrical discharge machining (EDM) a workpiece, the system comprising:
an electrode operatively coupled with and moveable by a guide assembly; and
an electronic controller operatively coupled with the electrode and the guide assembly, the electronic controller being configured to:
position a first end of an electrode in a direction of an alignment point located along a longitudinal axis intersecting the workpiece;
apply a voltage to the electrode effective to generate a spark, rotate the electrode at an angle relative to the longitudinal axis, and move the electrode relative to the alignment point by a first distance effective to create a first orifice section in the workpiece; and
adjust the voltage applied to the electrode, adjust the angle of rotation of the electrode relative to the longitudinal axis, and move the electrode relative to the alignment point by a second distance effective to create a second orifice section in the workpiece;
wherein a first flow area of the first orifice section is greater than a second flow area of the first orifice section.
9. The system of claim 8 , wherein the electronic controller is configured to:
second adjust the voltage applied to the electrode, second adjust the angle of rotation of the electrode relative to the longitudinal axis, and move the electrode relative to the alignment point by a third distance effective to create a third orifice section in the workpiece; and
third adjust the voltage applied to the electrode, third adjust the angle of rotation of the electrode relative to the longitudinal axis, and move the electrode relative to the alignment point by a fourth distance effective to create a fourth orifice section in the workpiece.
10. The system of claim 9 , wherein the first orifice section, the second orifice section, the third orifice section, and the fourth orifice section comprise portions of a venturi shape.
11. The system of claim 9 , wherein the first orifice section and the second orifice section comprise at least a portion of an outlet section of the orifice, the third orifice section comprises at least a portion of a middle section of the orifice, and the fourth orifice section comprises at least a portion of an inlet section of the orifice.
12. The system of claim 11 , wherein a diameter of the outlet section of the orifice has a diameter greater than a diameter of the middle section of the orifice, and a diameter of the inlet section of the orifice has a diameter that is greater than the diameter of the middle portion of the orifice.
13. The system of claim 8 , further comprising the workpiece.
14. The system of claim 13 , wherein the workpiece comprises at least a first portion of a fuel injector nozzle and the orifice is an injection orifice of the fuel injector nozzle.
15. The system of claim 8 , wherein the electronic controller is configured to identify the alignment point of the workpiece, the alignment point being located along a central longitudinal axis of the workpiece.
16. An apparatus comprising:
a nontransitory memory medium configured to store instructions for operating an electrical discharge machining (EDM) system including an electrode operatively coupled with and positionable by a guide assembly, the instructions being executable by a controller to control the electrode and the guide assembly to:
position a first end of an electrode in a direction of an alignment point located along a longitudinal axis intersecting the workpiece;
apply a voltage to the electrode effective to generate a spark, rotate the electrode at an angle relative to the longitudinal axis, and move the electrode relative to the alignment point by a first distance effective to create a first orifice section in the workpiece; and
modify the voltage applied to the electrode, modify the angle of rotation of the electrode relative to the longitudinal axis, and move the electrode relative to the alignment point by a second distance effective to create a second orifice section in the workpiece;
wherein a first flow area of the first orifice section is greater than a second flow area of the first orifice section.
17. The apparatus of claim 16 , wherein the instructions are executable by the controller to:
second modify the voltage applied to the electrode, second modify the angle of rotation of the electrode relative to the longitudinal axis, and move the electrode relative to the alignment point by a third distance effective to create a third orifice section in the workpiece; and
third modify the voltage applied to the electrode, third modify the angle of rotation of the electrode relative to the longitudinal axis, and move the electrode relative to the alignment point by a fourth distance effective to create a fourth orifice section in the workpiece.
18. The apparatus of claim 17 , wherein the first orifice section, the second orifice section, the third orifice section, and the fourth orifice section comprise portions of a venturi shape.
19. The apparatus of claim 16 , further comprising the controller.
20. The apparatus of claim 16 , further comprising the EDM system.