Abstract: The polishing system includes a power supply. The polishing system also includes a container including an interior portion. The interior portion includes a conductive material thereon. The conductive material is electrically coupled to the power supply. The polishing system also includes an electrolytic solution disposed within the container. The electrolytic solution includes a plurality of abrasive particles. The polishing system further includes a flexible media disposed within the container. The container is configured to contain an object. The power supply configured to electrically couple to the object. Each of the electrolytic solution, the flexible media, and the abrasive particles is configured to partially polish the object substantially simultaneously.

Abstract: A system is configured for machining a workpiece of a lattice structure, the system includes an electrode of a lattice structure, an electrolyte supply, and a power supply. The workpiece and the electrode are intertwined with each other and electrically isolated from each other. The electrolyte supply is configured for circulating an electrolyte around and between the workpiece and the electrode. The power supply is configured for applying a voltage between the workpiece and the electrode to facilitate smoothing surfaces of the workpiece.

Abstract: A milling tool is disclosed. The tool may include a base including a clamp for coupling to a selected mounting slot of a plurality of slots of the rotor; a milling tool including a motorized milling head; and a motorized linear actuator coupling the milling tool to the base. The base mounts the motorized linear actuator at an acute angle relative a portion of the slot to allow the motorized linear actuator to linearly move the milling tool to machine the portion of the slot. The portion of the slot may include, for example, an end face and, more particularly, a root corner of the slot where a cooling slot flange extends from the root of the slot. The milling tool may be portable.

Abstract: An electrochemical machining system for machining a conductive work piece is provided. The system includes a drilling tool configured to remove material from the conductive work piece. The drilling tool is configured to advance within the conductive work piece along a tool path to form a bore hole having a variable geometry that extends through the conductive work piece when the material is removed therefrom. The system further includes an inspection device configured to determine a position of the drilling tool along the tool path, and a controller configured to communicate with the inspection device. The controller is further configured to compare the tool path to a nominal tool path, and determine a position error of said drilling tool, the position error defined by a difference between the tool path and the nominal tool path.

Abstract: A drilling tool for use in machining a conductive work piece is provided. The tool includes a body portion, a forward electrode coupled to the body portion, and at least one side electrode coupled to the body portion. When electric current is supplied to the forward electrode and the at least one side electrode, material adjacent to the forward electrode and the at least one side electrode is removed from the conductive work piece. Further, the forward electrode and the at least one side electrode are selectively operable to form a bore hole having a variable geometry that extends through the conductive work piece when the material is removed therefrom.

Abstract: A drilling tool for use in machining a conductive work piece is provided. The tool includes a forward electrode tip that includes an outer radial portion and an inner radial portion that extends from a forward face of the outer radial portion. The tool also includes a dielectric sheath that extends circumferentially about the outer radial portion, and at least one side electrode coupled to the dielectric sheath. When electric current is supplied to the forward electrode tip and the at least one side electrode, material adjacent to the forward electrode tip and the at least one side electrode is removed from the conductive work piece. The forward electrode tip and the at least one side electrode are selectively operable to form a bore hole having a variable geometry that extends through the conductive work piece when the material is removed therefrom.

Abstract: Electrochemical machining of parts employs electric or voltage pulses in which current flows in a first direction and a second direction opposite from the first direction. The cathodic/anodic pulses switch between bulk machining and oxide removal pushing bulk material removal into a homogenous regime to obtain a smooth surface finish and appropriate form control during the electrochemical machining process compared to electrochemical machining employing an electric or voltage potential in which current flows in only one direction.

Abstract: A method for electroerosion machining includes providing an electrode assembly comprising an electrode body having a tube-shaped body that defines a hollow interior and one or more inserts affixed to the electrode body to form a cutting surface on the electrode assembly, positioning the electrode assembly adjacent a workpiece to be machined, and providing power to the electrode assembly so as to energize the electrode assembly, with the electrode assembly and the workpiece being at opposite electrical polarities. The method also includes advancing the electrode assembly through the workpiece, with a working gap being maintained between the inserts and the workpiece across which a pulse electric current is passed to remove material from the workpiece, wherein, upon advancing the electrode assembly through the workpiece, a core is formed that is completely separated from a remainder of the workpiece and is contained within the hollow interior of the electrode body.

Abstract: An electroerosion machining system for trepanning and drilling operations is disclosed. The electroerosion machining system includes an electrode assembly configured to machine a desired configuration in a workpiece, a power supply configured to energize the electrode assembly and the workpiece to opposite electrical polarities, an electrolyte supply configured to pass an electrolyte between the electrode assembly and the workpiece, a working apparatus configured to move the electrode assembly relative to the workpiece, and a control system to control the power supply and the working apparatus. The electrode assembly further includes an electrode body in the form of a tube-shaped body, the tube-shaped body defining a hollow interior and one or more replaceable inserts affixed to the electrode body at a working end thereof positioned adjacent the workpiece, the one or more replaceable inserts constructed so as to be selectively attachable and detachable from the working end of the electrode body.

Abstract: A component for a turbine engine includes a substrate that includes a first surface, and an insert coupled to the substrate proximate the substrate first surface. The component also includes a channel. The channel is defined by a first channel wall formed in the substrate and a second channel wall formed by at least one coating disposed on the substrate first surface. The component further includes an inlet opening defined in flow communication with the channel. The inlet opening is defined by a first inlet wall formed in the substrate and a second inlet wall defined by the insert.

Abstract: A milling tool is disclosed. The tool may include a base including a clamp for coupling to a selected mounting slot of a plurality of slots of the rotor; a milling tool including a motorized milling head; and a motorized linear actuator coupling the milling tool to the base. The base mounts the motorized linear actuator at an acute angle relative a portion of the slot to allow the motorized linear actuator to linearly move the milling tool to machine the portion of the slot. The portion of the slot may include, for example, an end face and, more particularly, a root corner of the slot where a cooling slot flange extends from the root of the slot. The milling tool may be portable.

Abstract: A method for electro-chemical machining (ECM) is provided. Methods may include providing an ECM machine including a controller and a fixture configured for positioning an electrode for ECM, positioning the fixture in a selected dovetail slot of a plurality of dovetail slots in a turbine wheel, the turbine wheel being positioned in-situ in a turbomachine, the fixture positioning the electrode for ECM of a portion of the selected dovetail slot, applying an electrolyte solution between the selected dovetail slot and the electrode, and removing material from the portion of the selected dovetail slot by applying an electric potential to the electrode to create a potential gradient between the electrode and the portion of the selected dovetail slot. The machining may be repeated for each dovetail slot of the turbine wheel in-situ in the turbomachine.

Abstract: A fixture for an electro-chemical machining (ECM) electrode is provided. The fixture may include a clamp having a shape and size configured to selectively engage in at least a portion of a selected dovetail slot of a plurality of dovetail slots in a turbine wheel. An electrode mount positions an electrode head relative to the clamp such that the electrode head operatively engages a portion of the selected dovetail slot for electro-chemical machining of the portion. The fixture's electrode may act as a cathode for the ECM process. The fixture allows for ECM on site without removing a turbine wheel from a turbomachine.

Abstract: A method of machining a work-piece formed of titanium-based material, using a machining apparatus, is described. The method includes the steps of providing an electrically-conductive electrode contained within a spindle assembly, in a pre-selected distance and position relative to the titanium-based work-piece; while electrically powering the electrode and the work-piece with a power supply. In the process, fluid electrolyte is circulated through at least two pathways in the machining apparatus—an internal conduit within the spindle assembly; and an external conduit. The charged electrode is moved relative to the work-piece in a plunging motion, to remove material from the work-piece at a relatively high rate, using a high-speed electro-erosion (HSEE) process.

Abstract: A method of machining a component including a substrate having an outer surface and an inner surface defining at least one interior space includes: disposing a distributed medium having a plurality of irregularly shaped particles in the interior space and forming at least one hole in the substrate, while the distributed medium is disposed within the interior space, such that the distributed medium provides backstrike protection for an opposing wall during the formation of the hole(s). Each hole extends through the substrate to provide fluid communication with the respective interior space; and the method further includes removing the distributed medium from the interior space.

Abstract: A system of manufacturing a component comprises forming a component on a conductive build plate. The component defines at least one access port and includes an inner surface that defines at least one internal passage. The system further includes forming at least one electrode within the at least one internal passage, wherein the at least one electrode is electrically isolated from the component. An electromotive force is applied to the at least one electrode to facilitate smoothing the inner surface.

Abstract: A method of manufacturing a component comprises forming a component on a conductive build plate. The component defines at least one access port and includes an inner surface that defines at least one internal passage. The method further includes forming at least one electrode within the at least one internal passage, wherein the at least one electrode is electrically isolated from the component. An electromotive force is applied to the at least one electrode to facilitate smoothing the inner surface.

Abstract: An electrochemical machining tool and method capable of rounding sharp edges that may be prone to cracking, for example, edge regions of cooling slots within dovetail slots of turbine wheels. The electrochemical machining tool includes an electrode and is secured to the component. The electrode of the electrochemical machining tool is inserted into a first slot, an electrolyte solution is applied between the electrode of the electrochemical machining tool and a second slot that intersects the first slot, an electrical potential is applied to the electrode and the turbine wheel to create a potential gradient between the electrode and the edge of the second slot, and material is removed from the edge of the second slot by displacing the electrode about and along the edge.

Abstract: A method of machining a component including a substrate having an outer surface and an inner surface defining at least one interior space includes: disposing a distributed medium having a plurality of irregularly shaped particles in the interior space and forming at least one hole in the substrate, while the distributed medium is disposed within the interior space, such that the distributed medium provides backstrike protection for an opposing wall during the formation of the hole(s). Each hole extends through the substrate to provide fluid communication with the respective interior space; and the method further includes removing the distributed medium from the interior space.

Abstract: A method for surface roughening a metal work piece includes disposing a region of the workpiece to be roughened proximate to a counter electrode. The region of the workpiece to be roughened and the counter electrode are subsequently disposed together in an electrolyte. An electric potential with current flow is applied between the work piece and the counter electrode to roughen the metal surface to a desired roughness.