Hydraulically operated electrochemical machining assemblies

An electrochemical machining assembly for boring a passage in an electrically conductive workpiece, the electrochemical machining assembly comprising:

• an electrochemical machining tool including a telescoping collar and an articulating head coupled to the telescoping collar, the telescoping collar having a contracted configuration and an extended configuration;
• an electrolyte circulation system configured to supply an electrolyte fluid to the electrochemical machining tool and receive the electrolyte fluid returning from the electrochemical machining tool;
• and
• a power supply configured to provide a voltage to the articulating head;
• wherein, the telescoping collar is hydraulically actuatable between the contracted configuration and the extended configuration responsive to fluid pressure provided by the electrolyte fluid to advance the telescoping collar stepwise in the passage;
• wherein, the articulating head is hydraulically tiltable relative to the telescoping collar responsive to fluid pressure provided by the electrolyte fluid to determine a direction of the passage;
• wherein, the articulating head has a pulsing degree of freedom relative to the telescoping collar that is hydraulically actuatable responsive to fluid pressure variations provided by the electrolyte fluid;
• and
• wherein, the electrochemical machining assembly is configured to remove material from the workpiece upon application of the voltage between the articulating head and the workpiece via the electrolyte fluid to lengthen the passage.

A method of boring a passage in an electrically conductive workpiece, the method comprising:

• positioning an electrochemical machining tool in the passage, the electrochemical machining tool including a telescoping collar and an articulating head coupled to the telescoping collar;
• circulating an electrolyte fluid through the electrochemical machining tool;
• injecting at least a portion of the electrolyte fluid into the passage forward of the articulating head;
• advancing the telescoping collar stepwise in the passage by hydraulically actuating the telescoping collar between contracted and extended configurations responsive to fluid pressure provided by the electrolyte fluid;
• determining a direction of the passage by tilting the articulating head relative to the telescoping collar;
• and
• lengthening the passage by applying a voltage between the articulating head and the workpiece via the electrolyte fluid to remove material from the workpiece.