Pulsed electrochemical machining

1 . A method for pulsed electrochemical machining (pECM) a workpiece, comprising:

generating a pulsed direct current between an electrode of a tool body of a pECM machining assembly and the workpiece, the tool body defining a tool axis, and the electrode comprising an electrically conductive material and defining a working surface at a first end configured to face the workpiece,

delivering an electrolyte through a plurality of apertures in the working surface into an interelectrode gap between the working surface of electrode and a target surface of the workpiece, wherein the plurality of apertures fluidically couple to an electrolyte system, wherein delivering the electrolyte through the plurality of apertures comprises:

flowing the electrolyte through a modular tool body which includes a manifold block, a first baffle element, the first baffle element defining a reservoir which at least partially equalizes electrolyte pressure above a plurality of baffle element apertures and the electrode;

replacing the first baffle element with a second baffle element different than the first baffle element; and

flowing the electrolyte through the modular tool body including the second baffle element; and

positioning the working surface of the electrode relative to the target surface of the workpiece to remove material from the target surface of the workpiece.

2 . The method of claim 1 , wherein the electrode defines the first end defining the working surface and a second end, each aperture of the plurality of apertures corresponds to a channel of a plurality of channels extending from the working surface at least partway through the electrode towards the second end of the electrode, and delivering electrolyte into the interelectrode gap includes flowing electrolyte through at least one channel of the plurality of channels.

3 . The method of claim 2 , wherein delivering electrolyte into the interelectrode gap comprises feeding electrolyte through at least one channel of a plurality of channels defined by the electrode, wherein the at least one channel extends through the electrode from the working surface to the second end.

4 . The method of claim 1 , wherein at least one channel of a plurality of channels is fluidically coupled to an electrolyte inlet defined by the manifold block.

5 . The method of claim 1 , wherein at least one channel of a plurality of channels is fluidically coupled to an electrolyte outlet defined by the manifold block.

6 . The method of claim 1 , wherein the electrode comprises a metal.

7 . The method of claim 1 , wherein the electrode is formed through additive manufacturing.

8 . The method of claim 1 , wherein the electrode is additively manufactured in a single, complete piece.

9 . The method of claim 1 , wherein delivering electrolyte into the interelectrode gap comprises distributing electrolyte with the first baffle element across the working surface through the plurality of apertures, wherein the plurality of apertures are evenly distributed across the workpiece.

10 . The method of claim 1 , wherein delivering electrolyte comprises delivering a greater volume of electrolyte to a central portion of the working surface than a perimeter portion of the working surface, wherein a surface area of the central portion is approximately equal to a surface area of the perimeter portion.

11 . The method of claim 10 , wherein the central portion defines a larger aperture area per unit area than the perimeter portion.

12 . The method of claim 1 , wherein the electrode defines the first end and a second end, and each aperture of a plurality of apertures corresponds to a channel extending from the first end of the electrode to the second end of the electrode,

wherein each channel of the plurality of channels defines a minimum cross-sectional area, and

wherein at least one first channel of the plurality of channels opens at the first end in a central portion of the working surface and at least one second channel of the plurality of channels open at the first end in a perimeter portion of the working surface, and

wherein each first channel of the at least one first channel opening into the central portion of the working surface defines a larger minimum cross-sectional area than each second channel of the at least one second channel opening into the perimeter portion of the working surface.

13 . The method of claim 1 , further comprising forming a seal between the tool body and a flow block.

14 . The method of claim 1 , further comprising pulling a vacuum through a channel in the electrode.

15 . The method of claim 1 , further comprising forming a seal around at least a portion of a perimeter of the first baffle element with the manifold block.

16 . A method for pulsed electrochemical machining (pECM) a workpiece, comprising:

generating a pulsed direct current between an electrode of a modular tool body and the workpiece to machine the workpiece; and

delivering an electrolyte into a working surface between the workpiece and the electrode during the pulsed direct current generation, wherein delivering the electrolyte comprises:

flowing an electrolyte through the modular tool body which includes a manifold block, a first baffle element, and the electrode to machine the workpiece during a first time period;

replacing the first baffle element with a second baffle element which imparts different flow characteristics to the electrolyte than the first baffle element; and

flowing the electrolyte through the modular tool body including the second baffle element to machine the workpiece during a second time period.

17 . The method of claim 16 , further comprising:

creating, during the first time period, a rough workpiece by flowing the electrolyte through the first baffle element, and

creating, during the second time period, a final workpiece by flowing electrolyte through the second baffle element.