Methods and systems of electrochemically machining are provided. The methods may include applying a first potential to a tool electrode of an electrochemical machining system to generate a primary electric field. The electrochemical machining system may include a workpiece opposite the tool electrode, at least one bias electrode, and at least one fluid delivery channel within the at least one bias electrode. The method may further include applying at least one second potential to the at least one bias electrode. The method may further include delivering a charged electrolyte solution through the at least one fluid delivery channel into the electrolyte solution. Applying at least one second potential and the delivering the charged electrolyte solution generates at least one secondary electric field adjacent to the primary electric field and quenches at least one location of the primary electric field.

A pulsed electrochemical machining (pECM) system including a pECM assembly. The pECM assembly includes a tool body which defines a tool axis and includes an electrode which includes an electrically conductive material and defines working surface. The pECM system includes an electrolyte system configured to supply electrolyte to an interelectrode gap, and the electrolyte system includes a vacuum system. The tool body defines a working surface configured to face a workpiece, and the working surface defines a plurality of apertures configured to fluidically couple to an electrolyte system. The tool body includes a manifold block defining at least one electrolyte inlet and at least one electrolyte outlet, a baffle element, and the electrode. The tool body is configured to receive electrolyte from an electrolyte system at the electrolyte inlet in the manifold block and feed electrolyte through the baffle element to the working surface of the electrode.

A pulsed electrochemical machining (pECM) system including a pECM assembly. The pECM assembly includes a tool body which defines a tool axis and includes an electrode which includes an electrically conductive material and defines working surface. The pECM system includes an electrolyte system configured to supply electrolyte to an interelectrode gap, and the electrolyte system includes a vacuum system. The tool body defines a working surface configured to face a workpiece, and the working surface defines a plurality of apertures configured to fluidically couple to an electrolyte system. The tool body includes a manifold block defining at least one electrolyte inlet and at least one electrolyte outlet, a baffle element, and the electrode. The tool body is configured to receive electrolyte from an electrolyte system at the electrolyte inlet in the manifold block and feed electrolyte through the baffle element to the working surface of the electrode.

The disclosure describes a method for defining an electrode of a pulsed electrochemical machining (pECM) tool that is performed by one or more processors. The method includes receiving workpiece measurement data representative of a machined surface of a machined workpiece. The machined workpiece has been machined by a working surface of an initial electrode. The method includes identifying a set of dimensional differences between the workpiece measurement data and workpiece model data representative of a finished surface of a master workpiece. The method includes updating, based on the set of dimensional differences, initial electrode model data representative of the working surface of the initial electrode and outputting the updated electrode model data.

The disclosure describes a method for defining an electrode of a pulsed electrochemical machining (pECM) tool that is performed by one or more processors. The method includes receiving workpiece measurement data representative of a machined surface of a machined workpiece. The machined workpiece has been machined by a working surface of an initial electrode. The method includes identifying a set of dimensional differences between the workpiece measurement data and workpiece model data representative of a finished surface of a master workpiece. The method includes updating, based on the set of dimensional differences, initial electrode model data representative of the working surface of the initial electrode and outputting the updated electrode model data.

A method and system for controlling machining accuracy of wire electrochemical trimming for a complex profile are provided. The method includes: obtaining a cross-sectional profile of a sample to be trimmed by wire electrochemical trimming; decomposing a cross-sectional profile of the sample to be trimmed by wire electrochemical trimming into straight line segments, convex arc segments, and concave arc segments; determining a mathematical relationship between a material removal depth and machining parameters during wire electrochemical trimming at each segment; substituting an arc curvature radius and a wire electrode radius that are obtained, as well as an average current density value and a wire electrode scan speed that are collected from experimental records or calculated through electric field simulation into the mathematical relationship, calculating a wire electrode scan speed for the concave arc segment and a wire electrode scan speed for the convex arc segment; performing wire electrochemical trimming.

A method and system for controlling machining accuracy of wire electrochemical trimming for a complex profile are provided. The method includes: obtaining a cross-sectional profile of a sample to be trimmed by wire electrochemical trimming; decomposing a cross-sectional profile of the sample to be trimmed by wire electrochemical trimming into straight line segments, convex arc segments, and concave arc segments; determining a mathematical relationship between a material removal depth and machining parameters during wire electrochemical trimming at each segment; substituting an arc curvature radius and a wire electrode radius that are obtained, as well as an average current density value and a wire electrode scan speed that are collected from experimental records or calculated through electric field simulation into the mathematical relationship, calculating a wire electrode scan speed for the concave arc segment and a wire electrode scan speed for the convex arc segment; performing wire electrochemical trimming.