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 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.

In the present invention, when performing electrical discharge machining on a workpiece via an electrical discharge machine that has an electrode holder and an electrode guide, a workpiece model and an electrode-guide model are generated in advance, an interference-start position at which the electrode-guide model starts interfering with the workpiece model when the electrode-guide model is moved towards the workpiece model along an axis line (CLa) is calculated, and a position obtained by moving the electrode-guide model a prescribed distance away from the workpiece model, starting at the interference-start position, is set as an electrode-guide position. With the electrode guide positioned at the electrode-guide position, the electrode holder is moved downwards in order to move an electrode downwards toward the workpiece surface, and electrical discharge machining is performed on the workpiece.

In the present invention, when performing electrical discharge machining on a workpiece via an electrical discharge machine that has an electrode holder and an electrode guide, a workpiece model and an electrode-guide model are generated in advance, an interference-start position at which the electrode-guide model starts interfering with the workpiece model when the electrode-guide model is moved towards the workpiece model along an axis line (CLa) is calculated, and a position obtained by moving the electrode-guide model a prescribed distance away from the workpiece model, starting at the interference-start position, is set as an electrode-guide position. With the electrode guide positioned at the electrode-guide position, the electrode holder is moved downwards in order to move an electrode downwards toward the workpiece surface, and electrical discharge machining is performed on the workpiece.

A method is provided for manufacturing a component. The method includes connecting a component comprising an internal passage and formed by an additive manufacturing process to a power supply, the component functioning as an anode, connecting a cathode to the power supply, the cathode being disposed in an electrolyte solution, the cathode being positioned externally to the internal passage of the component, contacting the internal passage of the component with the electrolyte solution, and using the power supply, applying a potential difference and current flow between the component and the cathode.

A method is provided for manufacturing a component. The method includes connecting a component comprising an internal passage and formed by an additive manufacturing process to a power supply, the component functioning as an anode, connecting a cathode to the power supply, the cathode being disposed in an electrolyte solution, the cathode being positioned externally to the internal passage of the component, contacting the internal passage of the component with the electrolyte solution, and using the power supply, applying a potential difference and current flow between the component and the cathode.

An apparatus includes an electrode assembly comprising a carriage having a plurality of electrode holders, the electrode holders being respectively configured to detachably receive a plurality of electrodes, the electrodes include a plurality of first electrodes and a plurality of second electrodes. The first electrodes are configured for rough machining a workpiece by electric discharging or wire electric discharging to remove material from the workpiece, the second electrodes are configured for finish machining the rough machined workpiece by electric discharging to remove material from the rough machined workpiece.

In an electrical discharge machine, the top end of a vertically extending electrode is supported by an electrode holder so as to be able to be raised and lowered, the circumferential surface of the bottom end of said electrode is supported by an electrode guide that is disposed so as to be able to move vertically with respect to the electrode holder, and the position of said electrode guide is detected by a position detection unit. This electrical discharge machine is provided with a work-tank raising/lowering device. During electrical discharge machining, said work-tank raising/lowering device raises/lowers a work tank, in accordance with the electrode-guide position (Hg) detected by the position detection unit, so as to set the distance from a prescribed part of the work tank to the electrode-guide position (Hg) equal to a prescribed value (Ha).

A method of forming a component for a gas turbine engine, including: casting a component around a ceramic core, wherein the ceramic core forms a pilot channel (40) in the component, the pilot channel oriented from a base (176) to a tip (20) of the component; sinking an ECM electrode into the pilot channel; and enlarging the pilot channel to form an inner surface of an external wall (120) of the component via electro-chemical machining, wherein a contour (94) of the inner surface is different than a contour of the pilot channel.

A method of forming a component for a gas turbine engine, including: casting a component around a ceramic core, wherein the ceramic core forms a pilot channel (40) in the component, the pilot channel oriented from a base (176) to a tip (20) of the component; sinking an ECM electrode into the pilot channel; and enlarging the pilot channel to form an inner surface of an external wall (120) of the component via electro-chemical machining, wherein a contour (94) of the inner surface is different than a contour of the pilot channel.