Abstract: An electrode containing a dielectric layer on a surface of the electrode and an active zone containing a metal embedded below the surface of the electrode, wherein the electrode is configured to form a groove pattern on a workpiece by an electrochemical machining process is disclosed. The electrode is capable of manufacturing a workpiece such as a counter plate, a sleeve journal or a conical bearing containing a groove pattern for fluid dynamics bearing, the groove pattern having a pitch of less than 80 microns. The electrode could be made by a method including depositing a dielectric layer on a surface of a metal, depositing a photoresist layer on the dielectric layer, printing a groove pattern on the photoresist layer, etching or physico-chemically removing portions of the dielectric photoresist layers to form grooves in the dielectric layer; removing the photoresist layer; and filling the grooves with a metal to produce the electrode.

Abstract: A system and method are described for ballizing and measuring a workpiece bore hole. In one embodiment, a ballizing unit having a distal end removably coupled to a ballizing member moves the ballizing member from a first position within the bore hole to a second position. A metrology unit having a distal end removably coupled to the ballizing member moves the ballizing member from the second position back to the first position. A sensor detects a force exerted on the ballizing member by the workpiece at a third position, which is located between the first and second positions.

Abstract: A cutting tool for machining stainless steel including a tool nose geometry with several facets. The tool includes a nose comprising a leading edge which chips and removes stock from the edge surface, the leading edge bearing adjacent a calibration edge post which the bore is rotated to thereby calibrate the bore. The calibration edge or facet has a length equal to the feed per revolution. This same side has a cutting angle length equal to zero. A hollow cathode discharge method of TiCN coating with no more than three micron thickness is used. This coating method creates a high density of plasma vapor, does not contain micro particles, produces a very dense film which completely replicates the finish of the surface being coated, prevents buildup and increases tool performance. The leading facet preferably has a cutting edge angle with the tool direction of travel through the bore surface equal to 45°.