Abstract: An electroerosion apparatus comprising: an electrode, a multiaxis machine, an electrolyte supply including a conduit for circulating an electrolyte, and a controller in operative communication with the multiaxis machine and configured for distributing intermittent multiple electrical arcs between the electrode and a workpiece. The multiaxis machine comprises a tool head configured to support and to spin the electrode, and a spindle configured to support a workpiece. The electrolyte comprises an anti-rusting agent, a defoaming agent, a lucent additive, a burst additive, a surface active medium, a lubricant, and water, and has a conductivity of about 0.1 milliSiemens to about 30 milliSiemens. In one embodiment, the method of electroerosion machining a workpiece comprises: creating relative motion between a spinning electrode and a workpiece; circulating an electrolyte around the spinning electrode, and distributing multiple electrical arcs between the electrode tip and the workpiece.

Abstract: An electromachining process and apparatus includes providing both high-speed electroerosion functions for rapidly rough finishing a workpiece and electrodischarge machining functions for fine finishing.

Abstract: In an electrochemical machining tool assembly having at least one electrode arranged across a gap from a workpiece, the electrode being energized by application of a potential difference ?V between the electrode and the workpiece, a method of monitoring machining includes exciting at least one ultrasonic sensor to direct an ultrasonic wave toward a surface of the electrode and receiving a reflected ultrasonic wave from the surface of the electrode using the ultrasonic sensor. The reflected ultrasonic wave includes a number of reflected waves from the surface of the electrode and from a surface of the workpiece. The method further includes delaying the excitation of the ultrasonic sensor a dwell time Td after a reduction of the potential difference ?V across the electrode and the workpiece occurs.

Abstract: A tandem blisk is mounted in a multiaxis electrochemical machine. A first row of blades is electrochemically machined in sequence. A second row of blades is then electrochemically machined in sequence while the blisk is still mounted in the machine. The machine is initially set up for machining both stages without removal of the blisk between the machining sequences.

Abstract: A method for monitoring machining in an electroerosion assembly having a power supply and an electrode arranged across a gap from a workpiece, includes measuring a voltage at a point in a voltage waveform after a time delay td of one half of a pulse width of the voltage waveform. The measurements are repeated for multiple pulses of the voltage waveform to obtain multiple voltages, each of the voltages corresponding to a point in respective pulses. The voltages are averaged to obtain an average voltage, which is compared with at least one threshold voltage, to determine whether the machining is in control. A control signal is generated if the comparison indicates that the process is not in control, the control signal being configured to regulate an operating parameter of the power supply, and the control signal is supplied to the power supply, if generated.

Abstract: An electroerosion apparatus includes a tubular electrode supported in a tool head in a multiaxis machine. The machine is configured for spinning the electrode along multiple axes of movement relative to a workpiece supported on a spindle having an additional axis of movement. A power supply powers the electrode as a cathode and the workpiece as an anode. Electrolyte is circulated through the tubular electrode during operation. And, a controller is configured to operate the machine and power supply for distributing multiple electrical arcs between the electrode and workpiece for electroerosion thereof as the spinning electrode travels along its feedpath.

Abstract: A flushing and filtering system for an electroerosion machine includes a work tank configured to maintain a workpiece therein, a first filtering stage for roughly filtering residue-containing machining liquid exiting from the work tank, and a second filtering stage for finely filtering roughly-filtered machining liquid exiting from the first filtering stage.

Abstract: In an electrochemical machining tool assembly having at least one electrode arranged across a gap from a workpiece, the electrode being energized by application of a potential difference ?V between the electrode and the workpiece, a method of monitoring machining includes exciting at least one ultrasonic sensor to direct an ultrasonic wave toward a surface of the electrode and receiving a reflected ultrasonic wave from the surface of the electrode using the ultrasonic sensor. The reflected ultrasonic wave includes a number of reflected waves from the surface of the electrode and from a surface of the workpiece. The method further includes delaying the excitation of the ultrasonic sensor a dwell time Td after a reduction of the potential difference ?V across the electrode and the workpiece occurs.

Abstract: A multi-axis machine, with numerical control on each axis, is used to drive the tool and workpiece movements necessary to machining complex airfoil geometry. Tooling is typically made of a metal such as brass or other low cost material and rotates during machining. The tooling may be any shape(cylindrical, conical) and size depending on application. A DC power (continuous or pulsed) is used to provide voltage across the tool and workpiece. A medium such as water, de-ionized water, or electrolyte (such as sodium nitrite) is provided between the tool and workpiece. Workpiece metal is removed in a controlled manner by high intensity thermal erosion.

Abstract: A ring or inverted-cup shaped cutting element is used as a tool electrode for electromachining to rough machine the airfoils on blisks to near net shape. The cutting element is rotated and positioned with respect to the blisk by a CNC (Computer Numerically Controlled) drive arrangement.

Abstract: A multi-axis machine, with numerical control on each axis, is used to drive the tool and workpiece movements necessary to machining complex airfoil geometry. Tooling is typically made of a metal such as brass or other low cost material and rotates during machining. The tooling may be any shape(cylindrical, conical) and size depending on application. A DC power (continuous or pulsed) is used to provide voltage across the tool and workpiece. A medium such as water, de-ionized water, or electrolyte (such as sodium nitrite) is provided between the tool and workpiece. Workpiece metal is removed in a controlled manner by high intensity thermal erosion.

Abstract: A ring or inverted-cup shaped cutting element is used as a tool electrode for electromachining to rough machine the airfoils on blisks to near net shape. The cutting element is rotated and positioned with respect to the blisk by a CNC (Computer Numerically Controlled) drive arrangement.