Abstract: A machining system is provided and includes a machining tool comprising a spindle, one or more electrodes configured to perform the electromachining, and one or more tool holding elements configure to conductively hold the respective one or more electrodes and be assembled onto the spindle of the machining tool. The machining system further comprises one or more adapters and one or more power sources configured to electrically connect to the respective one or more adapters and the workpiece. The one or more adapters are configured to conductively contact the respective one or more tool holding elements. Further, the machining system comprises one or more machining solution sources provided to pass one or more machining solutions between the workpiece and the respective one or more electrodes. A tool adapter assembly is also presented.

Abstract: A Method and machine tool for compensating a wear of an electrode that machines a workpiece. The method includes selecting a current pocket from plural pockets of the workpiece; updating a wear compensation to be applied to the electrode for the current pocket based on wear compensation of a previous pocket, where the previous pocket is adjacent to the current pocket; and applying the updated wear compensation to the electrode for machining the current pocket.

Abstract: An electroerosion machining system comprises one or more electrodes configured to machine a workpiece, a power supply configured to energize the workpiece and the respective one or more electrodes, an electrolyte supply configured to pass an electrolyte, and a working apparatus configured to move the respective one or more electrodes relative to the workpiece. The electroerosion machining system further comprises a controller configured to control the working apparatus to machine the workpiece, and a removal agent configured to cooperate with the electrolyte from the electrolyte supply for removal of removed material from the workpiece. An electroerosion machining method is also presented.

Abstract: An electroerosion machining system comprises an electrode, a power supply, an electrolyte supply, an electroerosion controller connected to and monitoring the power supply, and a working apparatus configured to move the electrode relative to the workpiece. The electroerosion machining system further comprises a CNC controller configured to cooperate with the electroerosion controller to control the working apparatus, and to calculate a wear value of the electrode. Further, the CNC controller is configured to segment the toolpath of every layer into a plurality of segments, and to divide the compensation value for every layer to be machined into a plurality of value segments, and further to use the value segments to compensate for electrode wear along the respective toolpath segments during machining of the workpiece. An electroerosion machining method is also presented.

Abstract: An electroerosion spindle assembly includes a main shaft, a tool electrode having a rear end directly or indirectly attached to the shaft and in alignment with the main shaft in a longitudinal direction, a container surrounding the main shaft, a stationary-to-rotary electrical conduction device mounted on the container for transitting power energy to the tool electrode, and a channel routing a flushing fluid to a front end of the tool electrode. The channel has at least one flushing slot in the container.

Abstract: An electroerosion control system includes a general CNC controller being configured for controlling a general CNC machine process, a power supply for energizing a tool electrode and a workpiece to be machined, an electroerosion controller electrically connecting with the power supply for controlling an output of the power supply, and adaptively and electrically connecting with the general CNC controller for communication thereof, and a sensor sensing real-time status information of a working gap between the tool electrode and the workpiece and for sending said real-time status information to said electroerosion controller. Said electroerosion controller automatically controls the electroerosion machining process through the general CNC controller according to the real-time status information of the working gap.

Abstract: An apparatus and method for adapting a CNC milling machine for electroerosion machining. The apparatus includes a tubular electrode on the distal end of an adapter shaft. A tool holder on the proximal end of the adapter shaft is mountable in the chuck of a cutter spindle in the milling machine. The adapter shaft is rotatably mounted within a bearing and an electrical brush contact subassembly, both of which are supported by a bracket. The bracket is attached to the milling machine but insulates it from the tool electrode. The bearing supports the adapter shaft in alignment with the CNC spindle. An electrical power supply energizes the electrode and the workpiece for electroerosion in a gap between them. Electrolyte is circulated through the spinning tool electrode during operation. The CNC computer is configured to operate the machine, power supply, and electrolyte flow for electroerosion machining.

Abstract: An electrochemical grinding electrode comprises an electrically conductive material; an arc resistance material; and an abrasive material different from the arc resistance material. An electrochemical grinding apparatus and a method are also presented.

Abstract: An electroerosion machining system comprises an electrode, a power supply, an electrolyte supply, an electroerosion controller connected to and monitoring the power supply, and a working apparatus configured to move the electrode relative to the workpiece. The electroerosion machining system further comprises a CNC controller configured to cooperate with the electroerosion controller to control the working apparatus, and to calculate a wear value of the electrode. Further, the CNC controller is configured to segment the toolpath of every layer into a plurality of segments, and to divide the compensation value for every layer to be machined into a plurality of value segments, and further to use the value segments to compensate for electrode wear along the respective toolpath segments during machining of the workpiece. An electroerosion machining method is also presented.

Abstract: A rough machining method for machining a channel in a workpiece includes the steps of: provide a power supply to energize one of a workpiece and an electrode as an anode and the other as a cathode; advance the electrode into the workpiece from a first start point to travel a first toolpath, so as to generate a first annular groove with a first core connecting with the workpiece; advance the electrode into the workpiece from a second start point to travel a second toolpath, so as to generate a second annular groove with a second core connecting with the workpiece, wherein the second annular groove intersects with the first annular groove and the first and the second cores are at least partially broken and disconnected with the workpiece upon intersecting of the first and the second annular grooves; and circulating a cutting fluid cross a working gap between a working face of the electrode and the workpiece.

Abstract: Disclosed herein is a compound electrode comprising a first portion comprising graphite; and a second portion comprising a metal; wherein the first portion is in continuous communication with the second portion along a length of the compound electrode. Disclosed herein too is a compound electrode comprising a first portion comprising graphite; and a second portion comprising a metal; wherein the first portion is in a tight fit with the second portion along a length of the compound electrode. Disclosed herein is a method comprising creating an electric arc between a compound electrode and a workpiece; wherein the compound electrode comprises a first portion comprising graphite; and a second portion comprising a metal; wherein the first portion is in a tight fit with the second portion along a length of the compound electrode; and removing a portion of the workpiece.

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: 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.