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.

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.

To provide a wire electric discharge machine which can appropriately perform thermal displacement correction of upper/lower guides even when the installation environment changes. Provided are a storage unit that stores temperatures of machine elements as temperature data, and a rendering unit that digitizes the installation environment and renders as environmental data. Additionally provided are a position command unit that commands a relative position of the upper/lower guides; and a relational expression calculation unit that sets the temperature data environmental data as input data, sets the relative position as training data, and calculates the relational expression by way of machine learning. Further provided are a relational expression decision unit that calculates a correction amount by substituting the temperature of the machine element into this relational expression, and in the case of error between the relative position of the upper/lower guides based on this correction amount and the relative position commanded by the position command unit being small, decides this relational expression as a formal relational expression; and a correction execution unit that performs correction on the relative position of the upper/lower guides using this relational expression.

To provide a wire electric discharge machine which can appropriately perform thermal displacement correction of upper/lower guides even when the installation environment changes. Provided are a storage unit that stores temperatures of machine elements as temperature data, and a rendering unit that digitizes the installation environment and renders as environmental data. Additionally provided are a position command unit that commands a relative position of the upper/lower guides; and a relational expression calculation unit that sets the temperature data environmental data as input data, sets the relative position as training data, and calculates the relational expression by way of machine learning. Further provided are a relational expression decision unit that calculates a correction amount by substituting the temperature of the machine element into this relational expression, and in the case of error between the relative position of the upper/lower guides based on this correction amount and the relative position commanded by the position command unit being small, decides this relational expression as a formal relational expression; and a correction execution unit that performs correction on the relative position of the upper/lower guides using this relational expression.

The invention provides a method for machining a shape such as slot or cavity or aperture using a plurality of first type holes (1) and second type holes (2), wherein during machining of first type holes (1) the hole circumference completely envelopes the respective portion of the electrode circumference.

Tool electrodes for and methods of electrical discharge machining are provided. In one exemplary aspect, a tool electrode for machining features into a workpiece is provided that allows for increased machining speed without sacrificing the quality of the machined features. Moreover, a tool electrode is provided that eliminates or reduces the high cost associated with customized tool electrodes. In particular, a tool electrode is provided that includes a plurality of electrode elements arranged and spaced apart in a digitized matrix representative of a tooling shape for machining features into a workpiece. The plurality of electrode elements are spaced apart from one another and arranged in the digitized matrix by digitizing an analog electrode tool configured to machine the feature into the workpiece or a volume of the feature to be machined into the workpiece.

Tool electrodes for and methods of electrical discharge machining are provided. In one exemplary aspect, a tool electrode for machining features into a workpiece is provided that allows for increased machining speed without sacrificing the quality of the machined features. Moreover, a tool electrode is provided that eliminates or reduces the high cost associated with customized tool electrodes. In particular, a tool electrode is provided that includes a plurality of electrode elements arranged and spaced apart in a digitized matrix representative of a tooling shape for machining features into a workpiece. The plurality of electrode elements are spaced apart from one another and arranged in the digitized matrix by digitizing an analog electrode tool configured to machine the feature into the workpiece or a volume of the feature to be machined into the workpiece.

A guide unit that stretches a wire electrode and guides the wire electrode to a machinable range section where a workpiece is placed includes: a first wire guide and a second wire guide; a first support element disposed spaced apart between the first and second wire guides and disposed spaced apart from the first wire guide, which determines a passage location of the wire electrode; and a second support element disposed spaced apart from the second wire guide, which determines a passage location of the wire electrode. The first support element has a variable direction relative to the first wire guide, the machinable range section of the wire electrode is formed of a portion stretched between the first and second support elements, and the wire electrode can tilt with respect to the wire electrode supplied from the supply unit.

A guide unit that stretches a wire electrode and guides the wire electrode to a machinable range section where a workpiece is placed includes: a first wire guide and a second wire guide; a first support element disposed spaced apart between the first and second wire guides and disposed spaced apart from the first wire guide, which determines a passage location of the wire electrode; and a second support element disposed spaced apart from the second wire guide, which determines a passage location of the wire electrode. The first support element has a variable direction relative to the first wire guide, the machinable range section of the wire electrode is formed of a portion stretched between the first and second support elements, and the wire electrode can tilt with respect to the wire electrode supplied from the supply unit.

Shape-tube electrochemical machining (STEM) systems, and methods of forming curved holes in components using STEM systems are disclosed. The systems may include a slider element, and an electrode coupled to the slider element. The electrode may include a linear body section, and a tip section. The tip section may be angled at a non-linear angle relative to the linear body section. The systems may also include a guide block slidably engaging the electrode. The guide block may include at least one aperture formed between a first and second section. The aperture(s) may receive the electrode. Additionally, the systems may include an electrode positioning block coupled to the linear body section of the electrode. The electrode positioning block may position the tip section of the electrode at a desired orientation relative to a component receiving the tip section to form a curved hole in the component.