A drilling tool for use in machining a conductive work piece that includes a forward electrode tip including an outer radial portion and an inner radial portion. The outer radial portion includes a forward face, and the inner radial portion extends from the forward face of the outer radial portion. The drilling tool further includes a dielectric sheath that extends circumferentially about the outer radial portion, at least one side electrode coupled to the dielectric sheath, and a protective sheath that extends circumferentially about the dielectric sheath. An opening is defined in the protective sheath such that the at least one side electrode is at least partially exposed.

A drilling tool for use in machining a conductive work piece that includes a forward electrode tip including an outer radial portion and an inner radial portion. The outer radial portion includes a forward face, and the inner radial portion extends from the forward face of the outer radial portion. The drilling tool further includes a dielectric sheath that extends circumferentially about the outer radial portion, at least one side electrode coupled to the dielectric sheath, and a protective sheath that extends circumferentially about the dielectric sheath. An opening is defined in the protective sheath such that the at least one side electrode is at least partially exposed.

A method of patterning a cylindrical tool, including providing a stamp including a base and a layer of solid state ionic conductor thereon, applying a negative of a predetermined pattern of features on a major surface of the solid state ionic conductor, providing a cylindrical tool having a metallic surface positioned proximate the stamp, and applying an electric field between the metallic surface and a cathode while moving the stamp against the metallic surface in rolling line contact so as to impart the predetermined pattern of features onto the metallic surface, wherein the cathode is either the base or a conductive element positioned adjacent to the base. The positive of the predetermined pattern of features may include a multiplicity of nano-sized features.

A method of manufacturing a gear, the method includes applying a first charge to a workpiece and applying a second, opposite charge to an electrochemical machining (ECM) attachment, the ECM attachment having a pattern. The method further includes simultaneously forming a plurality of surfaces of a gear tooth in the workpiece using the pattern of the ECM attachment while applying the first charge to the workpiece and applying the second charge to the ECM attachment and turning the workpiece and the ECM attachment in opposite rotational directions. The plurality of surfaces includes at least one end face and a top land of the gear tooth.

A method of manufacturing a gear, the method includes applying a first charge to a workpiece and applying a second, opposite charge to an electrochemical machining (ECM) attachment, the ECM attachment having a pattern. The method further includes simultaneously forming a plurality of surfaces of a gear tooth in the workpiece using the pattern of the ECM attachment while applying the first charge to the workpiece and applying the second charge to the ECM attachment and turning the workpiece and the ECM attachment in opposite rotational directions. The plurality of surfaces includes at least one end face and a top land of the gear tooth.

An electrochemical machining device includes a plurality of electrodes, a guiding member and a plate member. The electrodes are disposed around a workpiece. The guiding member is configured to limit and guide each of the electrodes to move. The plate member is configured to exert a force to each of the electrodes. The driving member is configured to rotate the workpiece. The plate member is connected to each of the electrodes. A force-exerting direction of the force from the plate member to each of the electrodes is parallel to a central axis of each of the electrodes or deflects off the central axis. Each of the electrodes is passed through the guiding member and configured to perform a machining on the workpiece which is rotated by the driving member, and each of the electrodes has an electrochemical machining direction which is perpendicular, oblique or parallel to the workpiece.

The present invention relates to an electrochemical machining apparatus for gear outline, which is used for trimming the gear outline of the gear part of a workpiece and comprises a first moving mechanism, a second moving mechanism, a cathode electrode, and a gear alignment member. The cathode electrode is disposed at the first moving mechanism. The second moving mechanism is connected with the gear alignment member. The gear alignment member includes a plurality of alignment gears for aligning the location of a plurality of teeth of the gear part of the workpiece. Thereby, the plurality of teeth of the workpiece may correspond to the cathode electrode. Then, the cathode electrode may perform electrochemical machining on the plurality of teeth, and thus, trimming the outline of the plurality of teeth.

A marker apparatus includes a housing, a current controller that is electrically connected to an electrode, a pad connected to the electrode for retaining an electrolytic fluid, and a removable cover. The removable cover retains an insulated stencil to an outer surface of the pad. The insulated stencil defines at least one permeable portion therein and a portion of the outer surface of the pad adjoins the at least one permeable portion. The at least one permeable portion can be formed as at least one opening defined through the insulated stencil, in which the portion of the outer surface of the pad extends into the at least one opening. The current controller provides an electric current from the electrode through the at least one permeable portion that is electrically connected to an object to be marker. The marker apparatus can include an on-board reservoir of electrolytic fluid and an actuator.

A marker apparatus includes a housing, a current controller that is electrically connected to an electrode, a pad connected to the electrode for retaining an electrolytic fluid, and a removable cover. The removable cover retains an insulated stencil to an outer surface of the pad. The insulated stencil defines at least one permeable portion therein and a portion of the outer surface of the pad adjoins the at least one permeable portion. The at least one permeable portion can be formed as at least one opening defined through the insulated stencil, in which the portion of the outer surface of the pad extends into the at least one opening. The current controller provides an electric current from the electrode through the at least one permeable portion that is electrically connected to an object to be marker. The marker apparatus can include an on-board reservoir of electrolytic fluid and an actuator.

There is disclosed a method of electro-chemically machining a cavity of a component using a flexible electrode. The flexible electrode comprises: a flexible core; a conductive body electrically coupled to the core; and a non-conductive body. The method comprises: inserting the flexible electrode through an opening and along the cavity, the non-conductive body engaging an internal wall of the cavity; and applying a negative charge to the flexible electrode, and providing a flow of electrolyte through the cavity to remove material from the internal wall.