An electrochemical machining apparatus is modular and includes a power module, an electrolyte processing module, an actuator module, and a control module that are connected with one another via a connection apparatus. The components are modular and are mounted on separate supports, many of which additionally include caster, and the connection apparatus is in the form of a removable umbilical. The modules can be individually moved to a location within a facility where a component is installed, and the modules can be interconnected to form the modular electrochemical machining apparatus at the location of the installed component. The apparatus can then perform an electrochemical machining operation in situ on the installed component.

An electrochemical machining apparatus is modular and includes a power module, an electrolyte processing module, an actuator module, and a control module that are connected with one another via a connection apparatus. The components are modular and are mounted on separate supports, many of which additionally include caster, and the connection apparatus is in the form of a removable umbilical. The modules can be individually moved to a location within a facility where a component is installed, and the modules can be interconnected to form the modular electrochemical machining apparatus at the location of the installed component. The apparatus can then perform an electrochemical machining operation in situ on the installed component.

The invention relates to a method machining a particularly planar component by means of electrochemical machining, wherein the component has internal stresses resulting particularly from preceding manufacturing steps. In a first step a) of the method, the component to be machined is provided. Subsequently, in step b), at least two tools are provided in the form of electrodes and, in step c), an electrolyte is provided between the component and the at least two electrodes. In step d), a positive voltage is applied to the component and a negative voltage is applied to the at least two electrodes. Thus, in step e), by moving the at least two electrodes along their respective movement paths with respect to the component, electrochemical machining can take place; in the process, the gap between each electrode and the component is flushed with the electrolyte at least intermittently.

The invention relates to a method machining a particularly planar component by means of electrochemical machining, wherein the component has internal stresses resulting particularly from preceding manufacturing steps. In a first step a) of the method, the component to be machined is provided. Subsequently, in step b), at least two tools are provided in the form of electrodes and, in step c), an electrolyte is provided between the component and the at least two electrodes. In step d), a positive voltage is applied to the component and a negative voltage is applied to the at least two electrodes. Thus, in step e), by moving the at least two electrodes along their respective movement paths with respect to the component, electrochemical machining can take place; in the process, the gap between each electrode and the component is flushed with the electrolyte at least intermittently.

A device and a method for producing a blade airfoil from a workpiece which comprises at least two gaps and at least one blank arranged between the two gaps, wherein the blank comprises two opposite lateral faces which are bounded by a base, a top and a first and a second edge. The method comprises: (a) arranging the first and second electrodes in the first and second gaps, the surface of the workpiece forming an annular space surface at the gaps, (b) applying a positive voltage to the blank and applying a negative voltage to the first and second electrodes, (c) moving the first and second electrode in the direction of the first and second lateral faces.

Step (b) is preceded by passing electrolyte between the two electrodes over the top toward the base.

A device (1) and a method for plasma-electrolytic machining of an electrically conductive surface (2) of a workpiece (3) are described. The device has an application unit (4) for applying an electrolyte jet to the surface (2), a supply unit (5) for at least temporarily supplying the application unit (4) with the electrolyte required to generate the electrolyte jet, at least one electrode (6), which forms a counter-electrode to the surface (2) during machining, and at least one electrical energy source (7), using which the electrode and the surface can be supplied with electrical energy during machining, such that a current flows between the electrode (6) and the surface (2) to be machined upon contact with the electrolyte.

The technical solution described is characterized in that the application unit (4) is designed to apply a first and at least one second electrolyte jet, which have different jet effect areas on the surface to be machined, simultaneously or consecutively to the surface (2) of the workpiece (3).

A device (1) and a method for plasma-electrolytic machining of an electrically conductive surface (2) of a workpiece (3) are described. The device has an application unit (4) for applying an electrolyte jet to the surface (2), a supply unit (5) for at least temporarily supplying the application unit (4) with the electrolyte required to generate the electrolyte jet, at least one electrode (6), which forms a counter-electrode to the surface (2) during machining, and at least one electrical energy source (7), using which the electrode and the surface can be supplied with electrical energy during machining, such that a current flows between the electrode (6) and the surface (2) to be machined upon contact with the electrolyte.

The technical solution described is characterized in that the application unit (4) is designed to apply a first and at least one second electrolyte jet, which have different jet effect areas on the surface to be machined, simultaneously or consecutively to the surface (2) of the workpiece (3).

An electrochemical machining assembly for boring a passage in an electrically conductive workpiece. The electrochemical machining assembly includes an electrochemical machining tool having a telescoping collar with an articulating head coupled thereto. The telescoping collar is hydraulically actuatable between a contracted configuration and an extended configuration responsive to fluid pressure provided by an electrolyte fluid circulated by the electrochemical machining assembly to advance the telescoping collar stepwise in the passage. The articulating head is tiltable relative to the telescoping collar to determine a direction of the passage. The electrochemical machining assembly is configured to remove material from the workpiece upon application of a voltage between the articulating head and the workpiece via the electrolyte fluid to lengthen the passage.

An electrochemical machining assembly for boring a passage in an electrically conductive workpiece. The electrochemical machining assembly includes an electrochemical machining tool having a telescoping collar with an articulating head coupled thereto. The telescoping collar is hydraulically actuatable between a contracted configuration and an extended configuration responsive to fluid pressure provided by an electrolyte fluid circulated by the electrochemical machining assembly to advance the telescoping collar stepwise in the passage. The articulating head is tiltable relative to the telescoping collar to determine a direction of the passage. The electrochemical machining assembly is configured to remove material from the workpiece upon application of a voltage between the articulating head and the workpiece via the electrolyte fluid to lengthen the passage.

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.