A method for the removal of debris (75) from an aperture (60), the aperture comprising a first aperture diameter (64) and extending along a first axis (62) over a first distance (63), the method comprising the steps of aligning a beam of energy (80) with the first axis such that the beam of energy is coaxially aligned with the aperture, the beam of energy comprising both an energy sufficient to remove the debris, and a first beam diameter (82) which is less than the first aperture diameter; and, exposing the debris to the beam of energy in order to remove the debris from the aperture.

An electrical discharge machining (EDM) system, control system and related methods. Various embodiments include a control system for controlling a plurality of electrode devices in an EDM system to form holes in a workpiece. The control system can be configured to perform a process including: initiating a hole formation program for each of the plurality of electrode devices; determining whether at least one electrode has completed formation of a corresponding hole in the workpiece; and separating at least one electrode from the workpiece in response to determining that at least one electrode has completed formation of the corresponding hole.

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.

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.

The present disclosure provides an electrochemical machining apparatus including a pressurized tank, a cap, a stabilizing plate, a guiding element, and an electrode. The pressurizing tank has a top surface and a chamber, wherein the top surface is disposed with an opening and a limiting portion. The cap fits in the opening and is limited by the limiting portion to seal the pressurized tank. The stabilizing plate is spaced from the top surface or the cap by a distance. The guiding element penetrates the stabilizing plate to connect with the cap and provides a channel to the chamber. The electrode is guided by the guiding element and penetrates the chamber via the channel. When the electrode processes a workpiece in the chamber during an electrochemical machining operation, the cap takes a pressure generated during the electrochemical machining operation, and the stabilizing plate stabilizes the electrode and the guiding element.

A grip unit including holding units in each of which an upper plate is placed on a lower plate to form a V-shaped groove, a grip unit control device that can change a distance between the holding unit in a range between a distance equal to or longer than a diameter of an electrode holder with an electrode feeding mechanism and a distance equal to a diameter of an electrode, a grip unit control device moving-shaft motor that can change a height of the grip unit in a range between a height at which the holding unit are placed lower than an electrode holder brim of an electrode holder having an electrode feeding mechanism attached to an electric holder gripping device and a height to which the holding units lift up the electrode holder brim of the electrode holder having an electrode feeding mechanism attached to the electric holder gripping device, and an electrode gripping device that can grip the electrode on a lower side of the grip unit are included. In one of the pair of holding units, a portion of the upper plate which forms the V-shaped groove is placed on a front side and a portion of the lower plate is placed on a rear side so as to overlap with each other. In the other one of the pair of holding unit, a portion of the lower plate which forms the V-shaped groove is placed on the front side and the upper plate is placed on the rear side so as to overlap with each other.

A method is provided comprising identifying an alignment point of a workpiece; positioning a first end of an electrode in the direction of the alignment point of the workpiece; applying a first voltage to the electrode wherein the applied first voltage generates a spark; rotating the electrode in a first direction; advancing the electrode toward the alignment point by a first distance wherein advancing the electrode and applying the first voltage creates a first orifice section; applying a second voltage to the electrode and modifying one or more operational parameters of the electrode; advancing the electrode toward the alignment point by a second distance wherein advancing the electrode and applying the second voltage causes formation of at least a second orifice section; wherein the first and second orifice sections cooperate to form an orifice comprising a first flow area and a second flow area.

There is provided a wire electric discharge machine including a calibrating unit which carries out calibration for obtaining a detected deviation amount of the tensile force detector based on the set tensile force and a tensile force detected by the tensile force detector when the set tensile force is applied, the calibrating unit correcting output of the tensile force detector by the detected deviation amount which is obtained by the calibration, and the wire electric discharge machine carries out feedback control of the tensile force of the wire electrode based on a corrected detected tensile force which is obtained by correcting the detected tensile force of the tensile force detector by the calibrating unit.

A machining apparatus is disclosed, which includes a curved outer conduit, a curved rotary electrode and a driving motor. The outer conduit has a cavity and a fluid inlet in fluid communication with the cavity. The electrode includes a flexible shaft positioned in the cavity and having a first end and a second end, and a machining head having a fluid outlet in fluid communication with the cavity and electrically connected with the first end of the flexible shaft to be powered via the flexible shaft. The motor is mechanically coupled to the second end of the flexible shaft for driving the flexible shaft to rotate. A machining system is also disclosed, which includes the machining apparatus, a power supply for powering the flexible shaft, an electrolyte supply for providing electrolyte to the fluid inlet and a machine tool onto which the outer conduit and the motor are positioned.

Modular tubing apparatuses for use in a shell-and-tube heat exchanger are described. Multiple apparatuses may be connected in series to form a high density, small tube diameter, long length tube apparatus assembly. Casting molds for forming modular tubing apparatuses are likewise described, including methods for casting and electrochemically machining such apparatuses.