Abstract: A machine tool system with a fixture plate for repeatably positioning and repositioning a workpiece relative to a tool is disclosed in this paper. In an illustrated embodiment, the system includes a tool base, a tool mounted to the tool base to move along a tool axis, and a fixture plate coupled to the tool base and supporting the workpiece for modification by the tool. The fixture plate shown in the example includes smooth-wall locating holes, threaded holes, elongated mounting holes, and an alignment bore. Openings included in the fixture plate allow for precise predetermined positioning of the workpiece relative to the tool.

Abstract: A pulsed electrochemical machining (pECM) system including a pECM assembly. The pECM assembly includes a tool body which defines a tool axis and includes an electrode which includes an electrically conductive material and defines working surface. The pECM system includes an electrolyte system configured to supply electrolyte to an interelectrode gap, and the electrolyte system includes a vacuum system. The tool body defines a working surface configured to face a workpiece, and the working surface defines a plurality of apertures configured to fluidically couple to an electrolyte system. The tool body includes a manifold block defining at least one electrolyte inlet and at least one electrolyte outlet, a baffle element, and the electrode. The tool body is configured to receive electrolyte from an electrolyte system at the electrolyte inlet in the manifold block and feed electrolyte through the baffle element to the working surface of the electrode.

Abstract: A machine tool system includes a workpiece, a machine, and a workpiece frame. The workpiece frame is repositionable and relocatable on the machine in at least two different orientations to support the workpiece in the at least two different orientations during modification of the workpiece so that different sides of the workpiece are modified without requiring removal of the workpiece from the workpiece frame.

Abstract: The disclosure describes a method for defining an electrode of a pulsed electrochemical machining (pECM) tool that is performed by one or more processors. The method includes receiving workpiece measurement data representative of a machined surface of a machined workpiece. The machined workpiece has been machined by a working surface of an initial electrode. The method includes identifying a set of dimensional differences between the workpiece measurement data and workpiece model data representative of a finished surface of a master workpiece. The method includes updating, based on the set of dimensional differences, initial electrode model data representative of the working surface of the initial electrode and outputting the updated electrode model data.

Abstract: A pulsed electrochemical machining (pECM) system includes a pECM tool comprising a tool body defining a tool axis, the tool body comprising one or more electrodes, each of the one or more electrodes comprising an electrically conductive material and defining a working surface at a distal end of the tool axis configured to face a workpiece; an enclosure system configured to hold the workpiece, wherein the enclosure system comprises: a first clamp configured to grip a first end of the workpiece; a second clamp configured to grip a second end of the workpiece; and a backside support configured to support a span of the workpiece between the first end and the second end.

Abstract: A pulsed electrochemical machining (pECM) system including a pECM assembly. The pECM assembly includes a tool body which defines a tool axis and includes an electrode which includes an electrically conductive material and defines working surface. The pECM system includes an electrolyte system configured to supply electrolyte to an interelectrode gap, and the electrolyte system includes a vacuum system. The tool body defines a working surface configured to face a workpiece, and the working surface defines a plurality of apertures configured to fluidically couple to an electrolyte system. The tool body includes a manifold block defining at least one electrolyte inlet and at least one electrolyte outlet, a baffle element, and the electrode. The tool body is configured to receive electrolyte from an electrolyte system at the electrolyte inlet in the manifold block and feed electrolyte through the baffle element to the working surface of the electrode.

Abstract: A pulsed electrochemical machining (pECM) system including a tool body defining a tool axis and a proximal end and a distal end. The tool body includes one or more electrodes, each of the one or more electrodes defining a working surface at the distal end of the tool axis configured to face a workpiece. Electrolyte at least partially fills an interelectrode gap defined by the working surface at the distal end of the tool axis and a target surface of the workpiece. A first flow block coupled to the tool body and a second flow block coupled to the workpiece are configured to form at least one seal surrounding at least a portion of a perimeter of the interelectrode gap, and the at least one seal is configured to reduce or eliminate flow of the electrolyte out of the portion of the perimeter of the interelectrode gap.

Abstract: In some examples, a pulsed electrochemical machining (pECM) system including a first tool body including a first electrode defining a working surface at a distal end of the tool axis configured to face a workpiece and a second tool body including a second electrode defining a working surface at a distal end of the tool axis configured to face a workpiece. The system includes a mechanical system configured to position the working surface of the first tool body relative to the workpiece and configured to position the working surface of the second tool body relative to the workpiece. The system includes an electrolyte system configured to supply electrolyte to a first interelectrode gap and a second interelectrode gap and a power supply configured to generate a pulsed direct current between the first tool body and the workpiece and the second tool body and the workpiece.

Abstract: In some examples, pulsed electrochemical machining (pECM) system, including an pECM tool comprising a tool body, the tool body comprising an electrode defining a working surface configured to oppose a workpiece during a pECM process; an electrolyte system configured to supply electrolyte to an interelectrode gap between the working surface of the electrode and a target surface of the workpiece; and a power supply configured to generate a pulsed direct current between the one or more electrodes of the pECM tool and the workpiece during the pECM process. The electrode includes an oxidation resistant layer defining at least a portion of the working surface, and a diamond-like carbon coating that defines another surface of the electrode.

Abstract: A pulsed electrochemical machining (pECM) system including a pECM assembly. The pECM assembly includes a tool body which defines a tool axis and includes an electrode which includes an electrically conductive material and defines working surface. The pECM system includes an electrolyte system configured to supply electrolyte to an interelectrode gap, and the electrolyte system includes a vacuum system. The tool body defines a working surface configured to face a workpiece, and the working surface defines a plurality of apertures configured to fluidically couple to an electrolyte system. The tool body includes a manifold block defining at least one electrolyte inlet and at least one electrolyte outlet, a baffle element, and the electrode. The tool body is configured to receive electrolyte from an electrolyte system at the electrolyte inlet in the manifold block and feed electrolyte through the baffle element to the working surface of the electrode.

Abstract: A pulsed electrochemical machining (pECM) system including a pECM assembly. The pECM assembly includes a tool body which defines a tool axis and includes an electrode which includes an electrically conductive material and defines working surface. The pECM system includes an electrolyte system configured to supply electrolyte to an interelectrode gap, and the electrolyte system includes a vacuum system. The tool body defines a working surface configured to face a workpiece, and the working surface defines a plurality of apertures configured to fluidically couple to an electrolyte system. The tool body includes a manifold block defining at least one electrolyte inlet and at least one electrolyte outlet, a baffle element, and the electrode. The tool body is configured to receive electrolyte from an electrolyte system at the electrolyte inlet in the manifold block and feed electrolyte through the baffle element to the working surface of the electrode.

Abstract: The disclosure describes a method for defining an electrode of a pulsed electrochemical machining (pECM) tool that is performed by one or more processors. The method includes receiving workpiece measurement data representative of a machined surface of a machined workpiece. The machined workpiece has been machined by a working surface of an initial electrode. The method includes identifying a set of dimensional differences between the workpiece measurement data and workpiece model data representative of a finished surface of a master workpiece. The method includes updating, based on the set of dimensional differences, initial electrode model data representative of the working surface of the initial electrode and outputting the updated electrode model data.

Abstract: A pulsed electrochemical machining (pECM) system includes a pECM tool comprising a tool body defining a tool axis, the tool body comprising one or more electrodes, each of the one or more electrodes comprising an electrically conductive material and defining a working surface at a distal end of the tool axis configured to face a workpiece; an enclosure system configured to hold the workpiece, wherein the enclosure system comprises: a first clamp configured to grip a first end of the workpiece; a second clamp configured to grip a second end of the workpiece; and a backside support configured to support a span of the workpiece between the first end and the second end.

Abstract: A pulsed electrochemical machining (pECM) system including a tool body defining a tool axis and a proximal end and a distal end. The tool body includes one or more electrodes, each of the one or more electrodes defining a working surface at the distal end of the tool axis configured to face a workpiece. Electrolyte at least partially fills an interelectrode gap defined by the working surface at the distal end of the tool axis and a target surface of the workpiece. A first flow block coupled to the tool body and a second flow block coupled to the workpiece are configured to form at least one seal surrounding at least a portion of a perimeter of the interelectrode gap, and the at least one seal is configured to reduce or eliminate flow of the electrolyte out of the portion of the perimeter of the interelectrode gap.

Abstract: The disclosure describes a pulsed electrochemical machining (pECM) tool that includes a tool body defining a tool axis and including one or more electrodes. Each of the one or more electrodes includes an electrically conductive material and defines a working surface at a distal end of the tool axis configured to face a workpiece. An electrical conductivity of at least one electrode varies across the working surface of the respective electrode.

Abstract: In some examples, a pulsed electrochemical machining (pECM) system including a first tool body including a first electrode defining a working surface at a distal end of the tool axis configured to face a workpiece and a second tool body including a second electrode defining a working surface at a distal end of the tool axis configured to face a workpiece. The system includes a mechanical system configured to position the working surface of the first tool body relative to the workpiece and configured to position the working surface of the second tool body relative to the workpiece. The system includes an electrolyte system configured to supply electrolyte to a first interelectrode gap and a second interelectrode gap and a power supply configured to generate a pulsed direct current between the first tool body and the workpiece and the second tool body and the workpiece.

Abstract: An electrochemical machining system includes an anodic workpiece of an electrically conductive metal, and an electrically conductive metallic cathodic tool with an external surface configured to machine the anodic workpiece. At least a portion of the external surface of the cathodic tool has a coating of diamond-like carbon (DLC). The system further includes a current source configured to apply a pulsed direct current to the anodic workpiece and the cathodic tool, and an electrolyte between the anodic workpiece and the cathodic tool.