{"id":697,"date":"2020-07-20T13:50:00","date_gmt":"2020-07-20T13:50:00","guid":{"rendered":"http:\/\/techtransfer.euro-fusion.eu\/?p=697"},"modified":"2022-02-28T15:14:17","modified_gmt":"2022-02-28T15:14:17","slug":"process-for-pilot-hole-fabrication-in-wire-cutting-electrical-discharge-machining-edm-to-improve-length-diameter-ratio-and-precision","status":"publish","type":"post","link":"http:\/\/techtransfer.euro-fusion.eu\/index.php\/2020\/07\/20\/process-for-pilot-hole-fabrication-in-wire-cutting-electrical-discharge-machining-edm-to-improve-length-diameter-ratio-and-precision\/","title":{"rendered":"Process for pilot hole fabrication in wire cutting (Electrical Discharge Machining, EDM) to improve length\/diameter-ratio and precision"},"content":{"rendered":"\n
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Sourcing new fusion technologies everywhere in Europe to foster your innovation… <\/em> <\/p><\/blockquote>\n<\/div><\/div>\n\n\n\n

Abstract<\/h3>\n\n\n\n

Developed at KIT (Karlsruhe Institute of Technology) for Test-Blanket-Module components, this technology offers increases limits in length\/diameter ratio and precision (drift) of pilot holes used for Electrical Discharge Machining (wire cutting). Instead of fabricating a start hole e.g. by deep-hole drilling, grooves are machined into the surface of bodies by standard machining. The bodies are then joined together using diffusion welding. Thus, limits in terms of length\/diameter ration as well as drift along the drill axis can be eliminated. This fusion based technology and know-how could now find promising applications in the field of hard metal processing companies and EDM equipment manufacturers. <\/em><\/p>\n\n\n\n

DOWNLOAD THE TECHNOLOGY DESCRIPTION<\/a><\/div>\n\n\n\n

Description of the Technology<\/h3>\n\n\n\n

The\ntechnology has been developed to overcome limits in pilot hole fabrication\nusing EDM (wire cutting). Nuclear fusion components, e.g. the First Wall are\npenetrated by cooling channels, one option for fabrication is EDM. Typical\nlength\/diameter ratios in this application are in the order of 200 and thus\nclose to (or even beyond) technological limits with regard to precision\nrequirements (drifting) in terms of deep-hole drilling. <\/p>\n\n\n\n

The\ntechnology described here was developed in order to increase limits in\nlength\/diameter ratio and precision (drift) of pilot holes used for Electrical\nDischarge Machining (wire cutting). Instead of fabricating a start hole e.g. by\ndeep-hole drilling, grooves are machined into the surface of bodies by standard\nmachining. The bodies are then joined together using diffusion welding. Thus,\nlimits in terms of length\/diameter ration as well as drift along the drill axis\ncan be eliminated. Length\/diameter-rations > 250 are reachable (e.g. channel\ndiameter 2 mm, length = 1000 mm is possible). KIT has also a strong expertise\nbehind the technology offer: innovative and flexible combination and\napplication of multiple manufacturing processes (EDM, forming, Additive\nManufacturing) and welding technologies.<\/p>\n\n\n\n

<\/p>\n\n\n\n

Innovation and advantages of the offer<\/h3>\n\n\n\n

The main innovation is to machine grooves into accessible surfaces of segments instead of drilling through a solid body. The surfaces are joined subsequently using Diffusion welding (Hot Isostatic Pressing). The precision limit in using this process routine is driven by standard machining tolerances since the surface is directly accessible while performing the tolerance-sensitive machining operation. Drifting of a drilling device during penetration of a solid is not applicable. To apply the joining operation, the machined grooves are aligned along each other that continuous cavities along the bonding surfaces are formed. Joining is performed in two steps: first by circumferential Electron Beam Welding inside of a vacuum chamber, subsequently inside a HIP -welding chamber at high pressure and temperature to create one solid body with internal penetrations.<\/p>\n\n\n\n

Non fusion applications<\/h3>\n\n\n\n

This fusion based technology and know-how could now find promising applications in the field of hard metal processing companies and EDM equipment manufacturers. Two examples of technologies from aircraft turbine combustion chamber manufacturing to circumvent length limits of cooling channels triggered by pilot hole manufacturing : Shorter segments (~ 300 mm channel length) assembled by EB-welding. Disadvantage: fusion welding seam crossing channels, Fabricate channels directly into a plate without pilot hole by cutting an entry slot directly into the outer surface with the cutting wire. Then manufacture channel and exit via the entry slot. The slot at the external side of the plate is closed subsequently, e.g. by soldering of welding.<\/p>\n\n\n\n

EUROfusion Heritage<\/h3>\n\n\n\n

The technology has been developed at KIT (Karlsruhe Institute of Technology is a technical university of the state of Baden-W\u00fcrttemberg and a national research centre in the Helmholtz-Gemeinschaft) during the nationally funded project BMBF-F\u00f6rderkennzeichen 03FUS0011: Test-Blanket-Module for ITER:\u00a0 Development and qualification of industrial manufacturing technologies. <\/p>\n","protected":false},"excerpt":{"rendered":"

Sourcing new fusion technologies everywhere in Europe to foster your innovation… Abstract Developed at KIT (Karlsruhe Institute of Technology) for Test-Blanket-Module components, this technology offers increases limits in length\/diameter ratio and precision (drift) of pilot holes used for Electrical Discharge Machining (wire cutting). Instead of fabricating a start hole e.g. by deep-hole drilling, grooves are […]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"ngg_post_thumbnail":0,"spay_email":""},"categories":[11],"tags":[],"jetpack_featured_media_url":"","_links":{"self":[{"href":"http:\/\/techtransfer.euro-fusion.eu\/index.php\/wp-json\/wp\/v2\/posts\/697"}],"collection":[{"href":"http:\/\/techtransfer.euro-fusion.eu\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"http:\/\/techtransfer.euro-fusion.eu\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"http:\/\/techtransfer.euro-fusion.eu\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"http:\/\/techtransfer.euro-fusion.eu\/index.php\/wp-json\/wp\/v2\/comments?post=697"}],"version-history":[{"count":3,"href":"http:\/\/techtransfer.euro-fusion.eu\/index.php\/wp-json\/wp\/v2\/posts\/697\/revisions"}],"predecessor-version":[{"id":701,"href":"http:\/\/techtransfer.euro-fusion.eu\/index.php\/wp-json\/wp\/v2\/posts\/697\/revisions\/701"}],"wp:attachment":[{"href":"http:\/\/techtransfer.euro-fusion.eu\/index.php\/wp-json\/wp\/v2\/media?parent=697"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"http:\/\/techtransfer.euro-fusion.eu\/index.php\/wp-json\/wp\/v2\/categories?post=697"},{"taxonomy":"post_tag","embeddable":true,"href":"http:\/\/techtransfer.euro-fusion.eu\/index.php\/wp-json\/wp\/v2\/tags?post=697"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}