This year, a major engineering redesign effort lead to an improved cathode of
oblong shape: two parallel sides spaced at 3.6 cm (1.4”), with semi-circular ends, and an
overall length of 8”. In addition to shape change, the advanced cutting process must meet
the following specifications:
1. The cutting tool must conform and allow penetration of a surface of
arbitrary curvature, including curvature in two dimensions of nonsymmetrical
shape.
2. The electrolyte must be kept at negative pressure to atmosphere and
thereby prevent or minimize leakage into the drum upon breakthrough.
3. The cutting procedure must be free of vibrations, high temperatures,
sparks and acoustic signals.
4. The system must be portable with a setup time of 10 minutes, with
penetration time of less than 15 minutes for a 2 mm thick work piece.
Using a heated electrolyte, we cut through a 1 mm thick drum of hardened steel in
8 minutes at a current of 100 A and a voltage of 4.6-5 V. The electrolyte was held at a
negative pressure to atmosphere. The cut was made on a cylindrical surface between
This year, a major engineering redesign effort lead to an improved cathode ofoblong shape: two parallel sides spaced at 3.6 cm (1.4”), with semi-circular ends, and anoverall length of 8”. In addition to shape change, the advanced cutting process must meetthe following specifications:1. The cutting tool must conform and allow penetration of a surface ofarbitrary curvature, including curvature in two dimensions of nonsymmetricalshape.2. The electrolyte must be kept at negative pressure to atmosphere andthereby prevent or minimize leakage into the drum upon breakthrough.3. The cutting procedure must be free of vibrations, high temperatures,sparks and acoustic signals.4. The system must be portable with a setup time of 10 minutes, withpenetration time of less than 15 minutes for a 2 mm thick work piece.Using a heated electrolyte, we cut through a 1 mm thick drum of hardened steel in8 minutes at a current of 100 A and a voltage of 4.6-5 V. The electrolyte was held at anegative pressure to atmosphere. The cut was made on a cylindrical surface between
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