Electrochemical Machining of Geometrically Complex Passages

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 actuatable between the contracted configuration and the extended configuration to advance the telescoping collar stepwise in the passage;
• wherein, the articulating head is tiltable relative to the telescoping collar to determine a direction of the passage;
• 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.