Pulsed electrochemical machining

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.