A system for forming features within composite components includes a tubular electrode extending along a longitudinal direction from a proximal end to a distal end. The distal end is, in turn, configured to be positioned relative to a machining surface of the composite component such that a spark gap is defined between the distal end and the machining surface. Furthermore, the tubular electrode further extends in a radial direction between an inner surface and an outer surface, with the inner surface defining a central passage configured to supply a dielectric fluid to the machining surface. The outer surface of the tubular electrode includes at least one a channel defined therein or a non-circular cross-sectional shape.

A power supply device for an electric discharge machine includes a DC power supply which is connected in parallel to an electrode gap, a plurality of switching elements which are in parallel to each other and which are arranged between the electrode gap and the DC power supply, a current value acquisition unit for acquiring a value of a current, and an ON-OFF control unit which, during the time when the current value reaches a predetermined value until the time when the current starts to fall, sets a cycle for switching the plurality of switching elements from off to on to the same cycle, switches the plurality of switching elements from off to on in a predetermined order for each timing of a phase of 90°, which is 360° divided by the number of the plurality of switching elements, sets an ON-period of each of the plurality of switching elements based on a difference between the value of the current and the predetermined value, and performs ON-OFF control of the plurality of switching elements based on the cycle, the timing, and the ON-period.

A power supply device for an electric discharge machine includes a DC power supply which is connected in parallel to an electrode gap, a plurality of switching elements which are in parallel to each other and which are arranged between the electrode gap and the DC power supply, a current value acquisition unit for acquiring a value of a current, and an ON-OFF control unit which, during the time when the current value reaches a predetermined value until the time when the current starts to fall, sets a cycle for switching the plurality of switching elements from off to on to the same cycle, switches the plurality of switching elements from off to on in a predetermined order for each timing of a phase of 90°, which is 360° divided by the number of the plurality of switching elements, sets an ON-period of each of the plurality of switching elements based on a difference between the value of the current and the predetermined value, and performs ON-OFF control of the plurality of switching elements based on the cycle, the timing, and the ON-period.

An electrode applied in electro-machining processes, where the electrode includes a main body portion and at least one built-in internal flushing passage for introducing a flushing liquid to a volume between the electrode and a workpiece to be machined. The electrode is made by an additive fabrication process that enables specialized flushing for enhancing waste material evacuation and incorporate special material properties like zones of high electrical conductivity and thermal resistance. The fabrication process produces materials and geometries that could not otherwise be made using conventional processing.

An electrode applied in electro-machining processes, where the electrode includes a main body portion and at least one built-in internal flushing passage for introducing a flushing liquid to a volume between the electrode and a workpiece to be machined. The electrode is made by an additive fabrication process that enables specialized flushing for enhancing waste material evacuation and incorporate special material properties like zones of high electrical conductivity and thermal resistance. The fabrication process produces materials and geometries that could not otherwise be made using conventional processing.

Electrode for an electro-erosion process, includes a shaft, a body coupled to the shaft, a plurality of machining-inserts, an insulated layer, and a flushing cover disposed on the body and coupled to the shaft. The shaft includes a channel, a plurality of first and second openings, each opening connected to the channel. The body includes a plurality of main-flushing channels, each channel connected to a corresponding first opening. The plurality of machining-inserts is spaced apart from each other along a circumferential direction and detachably coupled to a peripheral end portion of the body. Each machining-insert includes at least one third opening connected to a corresponding main-flushing channel. The insulated layer is disposed on top and bottom surfaces of the body. The flushing cover includes a plurality of side-flushing channels and a plurality of fourth openings, each channel connected to a corresponding second opening.

Electrode for an electro-erosion process, includes a shaft, a body coupled to the shaft, a plurality of machining-inserts, an insulated layer, and a flushing cover disposed on the body and coupled to the shaft. The shaft includes a channel, a plurality of first and second openings, each opening connected to the channel. The body includes a plurality of main-flushing channels, each channel connected to a corresponding first opening. The plurality of machining-inserts is spaced apart from each other along a circumferential direction and detachably coupled to a peripheral end portion of the body. Each machining-insert includes at least one third opening connected to a corresponding main-flushing channel. The insulated layer is disposed on top and bottom surfaces of the body. The flushing cover includes a plurality of side-flushing channels and a plurality of fourth openings, each channel connected to a corresponding second opening.

A gas path component for a gas turbine engine includes a film cooling hole disposed in the gas path component. The film cooling hole includes a metering section, a diffuser, and a tapered surface extending between the metering section and the diffuser. The tapered surface is oriented between twenty degrees and seventy degrees with respect to a centerline axis of the metering section. The tapered surface is oriented at an obtuse angle with respect to an immediately adjacent surface of the diffuser, the obtuse angle is open towards the centerline axis. The tapered surface is configured to mitigate flow separation in the diffuser.

A gas path component for a gas turbine engine includes a film cooling hole disposed in the gas path component. The film cooling hole includes a metering section, a diffuser, and a tapered surface extending between the metering section and the diffuser. The tapered surface is oriented between twenty degrees and seventy degrees with respect to a centerline axis of the metering section. The tapered surface is oriented at an obtuse angle with respect to an immediately adjacent surface of the diffuser, the obtuse angle is open towards the centerline axis. The tapered surface is configured to mitigate flow separation in the diffuser.

Methods of Electrical Discharge Machining (EDM) ceramic components are provided. In one aspect, a method includes electrical discharge machining a ceramic component, such as a Ceramic Matrix Composite (CMC) component. The ceramic component is electrical discharge machined while a contact matrix is positioned so that electrically conductive compliant and pressurized contacts of the contact matrix engage the ceramic component and so that an electrically conductive member of the contact matrix is in electrical conduction to a grounding structure.