WO2010039491A2

WO2010039491A2 - Electrolytic deburring apparatus and method

Info

Publication number: WO2010039491A2
Application number: PCT/US2009/057822
Authority: WO
Inventors: Michael R. Rohrbeck
Original assignee: Kennametal Inc.
Priority date: 2008-09-23
Filing date: 2009-09-22
Publication date: 2010-04-08
Also published as: US20100072077A1; WO2010039491A3

Abstract

Apparatuses and methods for toolless electrolytic deburring (100) are disclosed in which a charged electrolyte stream (134) flows through a hose (110) and nozzle (120) and can be selectively directed at a desired portion of an external or internal surface of a workpiece (102). The nozzle (120) or the workpiece (102) can be manipulated to vary the electrolytic deburring working gap so as to control the intensity of the electrolytic deburring and the portion of the workpiece that is electrolytically deburred. The electrolytic deburring is preferably performed in an enclosure (200) having a glove (210, 212) which has an electrical contact that can be used to electrically connect the workpiece (102) to the DC power supply anode(124) simply by gripping the workpiece.

Description

ELECTROLYTIC DEBURMNG APPARATUS AND METHOD

Field of the Invention

[0001] The present invention relates to apparatuses and methods for the toolless electrolytic deburring of metal workpieces.

Background of the Invention

[0002] Electrochemical surface machining ("ECM machining") may be used to remove small amounts of metal from the surfaces of metal workpieces. ECM machining has long been used for deburring, polishing, cleaning, passivating, and stress-relieving the surfaces of metal parts by electrochemically dissolving away the irregularities at the metal surface atom- by-atom. For simplicity of expression, these five different uses will be referred to singly and collectively hereinafter and in the appended claims as "deburring." The form of ECM machining that is used for deburring is sometimes referred to as "electrochemical deburring" and "electrolytic deburring." The latter term will be used hereinafter and in the appended claims to refer to ECM machining that is used for deburring.

[0003] In general, there are two kinds of conventional electrolytic deburring methods: (1) conformal tool electrolytic deburring, and (2) toolless electrolytic deburring. In both, the part of the metal workpiece that is to be deburred is exposed to an electrically conductive solution called an electrolyte. The workpiece is made to have a positive charge by electrically connecting it to the anode of a direct current ("DC") electrical power supply. One or more other pieces of metal are also placed into the electrolyte bath and are made to have a negative charge by electrically connecting it or them to the cathode of the power supply. This metal piece or pieces are referred to hereinafter and in the appended claims singly and collectively as the "working cathode" to distinguish it or them from the cathode of the power supply. When the power supply is turned on, a DC current flows between the anode and the cathode of the power supply through the workpiece. As the DC current flows, metal atoms are electrochemically removed from internal and external surfaces of the workpieces which are in contact with the electrolyte. The DC current is densest along the ridges, burrs, and sharp corners of the workpiece surface and so these features electrochemically dissolve away faster than does the rest of the workpiece surface. This preferential dissolution results in the smoothing of the metal surface, the removal of burrs, and the slight rounding of sharp corners. The electrolyte is flowed across the workpiece surface or the workpiece is oscillated in order to wash away the removed metal and to bring fresh electrolyte in contact with the workpiece surface to sustain the electrolytic action. Cycle times for electrolytic deburring generally are between 10 seconds and 3 minutes,

[0004] The main differences between the two conventional types of electrolytic deburring method are: (1) the configuration and placement of the working cathode, (2) the size of the gap between the workpiece and the bath electrode, and (3) the kind of electrolyte used. In conformal tool electrolytic deburring, the working cathode has a shaped surface that conforms to the desired final shape of the workpiece and must be placed very near the workpiece so that the workpiece can take on the complement of that shape. A small gap, generally less than 0.03 inches (0.75 millimeters), is maintained throughout the electrolytic deburring operation. The electrolyte is typically a highly conductive, strong salt solution. [0005] Toolless electrolytic deburring has its foundations in the technology disclosed in four U.S. patents which were issued to KarS-Imgemar Blomsterberg: U.S. Patent Nos. 4,269,677, which issued May 26, 1981; 4,405,422, which issued September 20, 1983; 4,411,751, which issued October 25, 1983; and 5,256,262, which issued October 26, 1993. In toolless electrolytic deburring, the working cathode need not conform to that of the desired final shape of the workpiece. Often, the working cathode is a flat plate or plates which are placed somewhere in the vicinity of the workpiece. A free-standing conductor that functions like antenna for the cathodic charge is sometimes used to act as a working cathode and may be inserted into a cavity of the workpiece for internal surface deburring. In toolless electrolytic deburring, it is not necessary to maintain a constant gap and the gap can be large, i.e., up to about a foot (30 centimeters). The electrolyte has a relatively higher resistance than that used in conformal tool electrolytic deburring. The electrolyte is also generally less hazardous and creates less hazardous by-products during the electrolytic deburring process than does the conformal tool electrolyte. [0006] Despite its advantages over conformal tool electrolytic deburring, toolless electrolytic deburring has some drawbacks. One is that the workpiece usually needs to be immersed into a bath of the electrolyte. A significant amount of electrolyte loss may occur when the workpieces are pulled out of the electrolyte bath. Another drawback is that fixturing is usually necessary to hold the workpiece in place during the process. The fixture also is needed to electrically connect the workpiece to the power supply anode. The fixtures gradually electrochemically dissolve away during use and scratches and other surface defects on a fixture can locally accelerated the electrochemical dissolution rate, shortening the fixture's useful lifetime. Another drawback is that while the conventional toolless electrolytic deburring process is well- suited to the simultaneous processing of multiple workpieces in production quantities, the cost of fixruring makes it is less-well suited to the processing of small quantities of workpieces.

[0007] More than a dozen years ago, an uncommercialized, abortive effort was made to overcome the need to immerse the workpiece in an electrolyte bath for toolless electro lytic deburring. A paper by James B. Koroskenyi, titled "Burlytic Deburring - A New Approach in Electrochemical Deburring," Society of Manufacturing Engineers, MR95-228 (1995), pp. 1-25, shows a fixture that was intended for use on a drained benchtop to flush electrolyte through workpieces so as to obviate the need of immersing the workpieces in an electrolyte bath and to further localize the deburring activity. However, the paper does not appear to disclose how the power supply cathode or anode were intended to be electrically connected into the electrical circuit necessary to accomplish the electrolytic deburring of the workpieces. The paper also does not disclose whether or not the fixture was ever successfully used for its intended purpose.

Summjary_^of the Invention

[0008] The present invention provides toolless electrolytic deburring methods and associated apparatuses that overcome at least some of the aforementioned drawbacks of the prior art. In particular, the methods and apparatuses of the present invention are particularly well-suited for toolless electrolytic deburring of individual workpieces, especially those which have areas that need more processing than other areas. The present invention makes it possible to toolless electrolytic deburr a workpiece without immersing it in a bath of electrolyte and without the use of a conventional working cathode. Moreover, the present invention allows the gap between its novel working cathode and a workpiece to be selectively varied in order to locally intensify or diminish the degree of deburring of a selected portion of the workpiece' s interna! or external surface. [0009] The present invention accomplishes these objectives by associating a novel working cathode with a flexible hose and nozzle from which flows a stream of electrolyte that can be selectively directed at any desired portion of the workpiece, including into or through internal cavities of the workpiece. The nozzle of the hose can be manipulated to vary the gap between the novel working cathode and the workpiece. In some embodiments of the present invention, the workpiece also can be selectively manipulated during the electrolytic deburring process to enable even more control over the intensity of the electrolytic deburring and the portion of the workpiece that is electrolytically deburred.

[OOIOJ In method embodiments of the present invention, an electrical power supply capable of selectively supplying DC current is provided for use. Preferably, the power supply is capable of selectively supplying pulsed DC current. The workpiece is electrically connected to the anode of the power supply. It should be understood that the term "electrically connected" is used herein and in the appended claims to mean that the objects which are described as being electrically connected to one another are situated so that an electrical current can flow directly or indirectly from one to the other. A stream of electrolyte is pumped through the flexible hose and exits the hose through a nozzle. Before exiting the nozzle, the stream is electrically connected to the cathode of the power supply. The nozzle is selectively manipulated to controllably impinge the stream upon a selected portion of the workpiece surface. The power supply is operated to flow a DC current between its cathode and its anode and through the workpiece. The process is continued until the desired degree of deburring of the workpiece has been achieved. [0011] The present invention also includes apparatuses for performing the method embodiments. In addition to the aforementioned power supply, flexible hose, and nozzle, the apparatuses include: a reservoir containing a quantity of the electrolyte; a pump adapted to move the electrolyte from the reservoir through the nozzle; and electrical leads for electrically connecting the electrolyte stream and the workpiece to, respectively, the power supply's cathode and anode during the toolless electrolytic deburring process. Some embodiments of the present invention also include an enclosure having a window through which an operator can view the workpiece during processing and a glove for receiving one of the operator's hands. The operator can use the glove to manipulate the workpiece, the anode lead, and/or the nozzle. The gripping area of the glove may be electrically connected to the power supply anode so that the operator can electrically connect the workpiece to the electrical lead by grasping the workpiece in the gripping area of the glove. Some embodiments of the present invention further include a second glove for receiving the operator's other hand. The second glove permits the operator to manipulate the nozzle and/or the workpiece. Some embodiments of the present invention include a gas jet, e.g., of compressed air, for blowing electrolyte off of the workpiece surfaces and cavities after the electrolytic deburring has been completed.

Brief Description of the Drawings

[0012] The criticaiity of the features and merits of the present invention will be better understood by reference to the attached drawing. It is to be understood, however, that the drawings are designed for the purpose of illustration only and not as a definition of the limits of the present invention.

[0013] FIG. 1 is a schematic of an apparatus for toolless electrolytic deburring a metal workpiece according to an embodiment of the present invention. [0014] FIG. 2 is a perspective view of an enclosure that is a part of an apparatus embodiment of the present invention.

[0015] FIG. 3 is a perspective view of a portion of a glove from the enclosure shown in FIG. 2.

[0016] FlG. 4. is a schematic showing an arrangement of a staging area, enclosure, and post-deburring handling area in accordance with an embodiment of the present invention.

of the Preferred Embodiments

In this section, some preferred embodiments of the present invention are described in detail sufficient for one skilled in the art to practice the present invention. It is to be understood, however, that the fact that a limited number of preferred embodiments are described herein does not in any way limit the scope of the present invention as set forth in the appended claims.

[0018] Referring to FIG. 1, there is shown a schematic representation of an apparatus 100 for toolless electrolytic deburring of a metal workpiece 102 according to an embodiment of the present invention. The apparatus 100 comprises a reservoir 104 containing a quantity of electrolyte 106, a pump 108, a flexible hose 110, a collector 112, and an electrical power supply 114 that is adapted to provide DC current, preferably pulsed DC current. The reservoir 104 is in fluid communication with the pump 108 via a pipe 116. One end of the hose 110 is operably connected to the pump outlet 118 and the other end is attached to a nozzle 120. The power supply 114 has a cathode 122 and an anode 124. A first electrical lead 126 has one end electrically connected to the cathode 122 and its other end electrically connected to the nozzle 120. A second electrical lead 128 has one end electrically connected to the anode 124 and its other end electrically connected to the workpiece 102. [0019] During operation, the power supply 114 provides a DC current between its cathode 122 and its anode 124 through the workpiece 102 in the following manner. The direction of flow of the electrolyte 106 is indicated by arrows, e.g., the arrow 130. The pump 108 draws in electrolyte 106 from the reservoir 104 through the pipe 116 and the pump inlet 132. The pump 108 forces the electrolyte 106 out through the pump outlet 118, into the hose 110, and out through the nozzle 120 as a stream 134. The stream 134 is electrically connected to the cathode 122 by way of the nozzle 120 and so has a negative charge as it exits the nozzle 120. The nozzle 120 is manipulated to direct the stream 132 at a desired portion of an exterior or interior surface of the workpiece 102. Its impact with the workpiece 102 breaks up the stream 132 causing the electrolyte 106 to flood across the surface of the workpiece 102 in the vicinity of the impact area. Since the workpiece 102 is electrically connected to the anode 124, the workpiece is positively charged and metal is electrochemically removed from the workpiece surface in the vicinity of the impact area of the stream 134. The post-impact electrolyte 106 flowing off of the workpiece 102 is directed by the collector 112 into the filter 136. The filter 136 removes the milling debris and other contaminants from the electrolyte 106 before the electrolyte 106 returns to the reservoir 104.

[0020] Due to its electrical connection to the cathode 122, the nozzle 120 is the working cathode of the apparatus 100 in this embodiment of the present invention. The length of the stream 134 represents the gap distance between the working cathode and the workpiece 102. By moving the nozzle 120 or the workpiece 102 closer or farther away from one another, the gap distance is changed and so is the intensity of the electrochemical action at the surface of the workpiece 102. The present invention thus permits dynamic control of the rate of metal removal during the electrolytic deburring process by changing the relative positions of the nozzle 120 and the workpiece 102 during the electrolytic deburring process.

[0021] By changing the electrolyte flow rate and/or the spray pattern of the stream 134, the intensity of the electrolytic deburring process can be further controlled. In some embodiments of the present invention, the flow rate of the electrolyte in the stream 134 is adjustable. The adjustments may be made by controlling the pumping speed of the pump 108 or by inserting a variable control valve 138 between the pump outlet 118 and the hose 110 or between the reservoir 104 and the pump inlet 132. Preferably, a variable control valve is incorporated into the nozzle 120 to permit adjusting both the flow rate and the spray pattern of the stream 134 and to allow controllable focusing of the stream 134 on portions of the surface of the workpiece 102 that are to be preferentially deburred. [0022] The apparatus 100 also includes a gas nozzle 140 at the end of a gas hose 142 which is in fluid communication with a gas source 144. The gas nozzle 140 selectively emits a gas jet 146 and can be selectively operated to blow away residual electrolyte 104 from the surface of the workpiece 102 at the end of the electrolytic deburring process. [0023] Optionally, a heat exchange unit, e.g., a chiller, may be included into the apparatus 100 to control the temperature of the electrolyte.

[0024] In preferred embodiments of the present invention, the electrolytic deburring process is conducted in an enclosure which acts to contain the splashings and overspray of the electrolyte stream. In addition to the workpiece 102, the enclosure also preferably encloses the flexible hose 110, the nozzle 120, the collector 112, the filter 136, the gas hose 142, the gas nozzle 140, and at least portions of the first and second electrical leads 126, 128. The power supply 114, the pump 108, and the electrolyte heat exchanger may also be contained within the enclosure, but are more preferably located outside of the enclosure.

[0025] Referring to FIG. 2, there is shown an example of such an enclosure, i.e., enclosure 200. Enclosure 200 has a window 202 through which an operator can view the workpiece 102 as it is being processed. A magnified inspection area 204 is provided in the window 202 to enable the operator to closely inspect the workpiece surface. Enclosure 200 also has two glove ports 206, 208 to which are attached insulated gloves 210, 212 for receiving the operators hands. The operator can use the gloves 210, 212 for manipulating the workpiece 102, the flexible hose 110 and the nozzle 120, the first and second electrical leads 126, 128, the gas hose 142, and the gas nozzle 140. The enclosure 200 also has an outside foot switch 214 by which the operator can control at least one of the DC current and the electrolyte flow. The enclosure 200 also has a fluid-tight, vertically-sliding door 216 and a handle 218 for the taking the workpiece 102 into and out of the enclosure 200. [0026] In some preferred embodiments of the present invention, the gripping area of one of the gloves 210, 212 is electrically connected to the second electrical lead 128 so that the operator can electrically connect the workpiece 102 to the anode 124 simply by grasping the workpiece 102. Referring to FIG. 3, there is shown an electrically insulated glove 210 having an electrically conductive contact pad 300 attached to its thumb 302. The contact pad 300 is electrically connected to the second electrical lead 128, which curls around the thumb 302 and runs down the backside of the glove 210. The contact pad 300 is located in the grasping area of glove 210 so that the operator can selectively electrically connect the workpiece 102 to the anode 124 simply by grasping the workpiece 102.

[0027] It should be understood that the present invention also contemplates other means of electrically connecting the workpiece to the anode, whether or not an enclosure is utilized. For example, during processing, the workpiece can be placed upon a conductive work table that is electrically connected to the anode or the workpiece can be placed into electrical connection with a portion of a fixture which is electrically connected to the anode. Another alternative, would be to physically connect an electrical lead directly to the workpiece.

[0028] In addition to having an enclosure, e.g., enclosure 200, some embodiments of the present invention also have a staging area and/or a post-dεburrmg handling area in operable communication with the enclosure. Referring to FIG. 4, there is shown a schematic depiction of an enclosure 200 that is in operable communication with both a staging area 400 and a post-deburring handling area 402. Vertically-sliding doors 404, 406, 408, 410 permit a workpiece to be brought into the staging area 400 and then transferred to the enclosure 200 and from there to the post- deburring handling area 402 and then to be removed therefrom. The staging area 400 may be used for holding one or more prc-cleaned workpieces or it may be used to clean and hold workpieces that are to be electrolytic deburred in enclosure 200. The post-deburring handling area 402 may be used as an area for washing electrolyte off of deburred workpieces. The staging area 400 and the post-deburring handling area 402 are preferably at least partly enclosed and may be portions of the enclosure 200. If enclosed, they preferably have means to either directly handle, e.g., glove ports, or remotely handle, e.g., robotic arms, the workpieces, but they may be completely open, e.g., platforms or worktables.

[0029] In the above discussion of the embodiment of the present invention depicted in FIG. 1, the nozzle 120 is the effective working cathode for the electrolytic deburring process. However, other means of providing a working electrode to impose a negative charge to the electrolyte stream 134 are within the contemplation of the present invention. For example, a portion of the flexible hose 110 may be lined with an electrical conductor that is electrically connected to the cathode 122, e.g., through the first electrical lead 126. Another example is to provide within the hose 110 or within the nozzle 120 an electrically conductive screen that the electrolyte passes through or an electrically conductive element that protrudes into the electrolyte, In any case, it is preferred that the outer surfaces of the hose 110 and the nozzle 120 be electrically insulated to avoid the occurrence of electrical shorts. [0030] Also as discussed above with regard to the embodiment of the present invention described in FIG. 1, it is preferred, although not necessary, that the apparatus include a means for providing a gas jet for blowing the residual electrolyte off of the internal and external surfaces of the workpiece. Any suitable gas may be used, but the gas is preferably filtered compressed air, nitrogen, argon, or a combination thereof.

[0031] The present invention utilizes a DC current power supply, preferably one that provides pulsed DC current. Such power supplies and the parameters for their use are well-known to those skilled in the art.

[0032] Similarly, the electrolyte that is to be used with embodiments of the present invention are known in the art and some are commercially available. Such a commercially available electrolyte is the CoolPulse® brand process electrolyte which may be obtained from Extrude Hone Corporation, Irwin, Pennsylvania, U.S. [0033] In method embodiments of the present invention for toolless eiectrolytically deburring a metal workpiece, an electrical power supply capable of selectively supplying DC current is provided for use. The workpiece is electrically connected to the anode of the power supply. A stream of electrolyte is pumped through the flexible hose and exits the hose through a nozzle. Before exiting the nozzle, the stream is electrically connected to the cathode of the power supply. The nozzle is selectively manipulated to controllably impinge the stream upon the workpiece or a selected portion of the workpiece. A variable control valve may be used to control the flow of the stream from the nozzle or the spray pattern of the stream. The nozzle or the workpiece may be moved to vary the distance between the nozzle and the workpiece. The power supply is operated to flow a DC current, preferably a pulsed DC current, between its cathode and its anode and through the workpiece. The process is continued until the desired degree of deburring of the workpiece has been achieved. In some preferred method embodiments of the present invention, the process is conducted within an enclosure, such as the enclosure 200 described above in relation to FIGS. 2-4 and the glove or gloves of the enclosure are used to manipulate at least one of the workpiece, an electrical lead that is electrically connected to the anode of the power supply, and the nozzle from which the electrolyte stream is emitted. At least one of the gloves may also be used for electrically connecting the workpiece to the anode by gripping the workpiece with the gripping area of the glove.

[0034] Some method embodiments of the present invention include using a gas jet to blow electrolyte off of a surface of the workpiece. The gas may be one selected from the group consisting of air, nitrogen, argon, or combinations thereof. [0035] While only a few embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that many changes and modifications may be made thereunto without departing from the spirit and scope of the present invention as described in the following claims. All patent applications and patents, both foreign and domestic, and all other publications referenced herein are incorporated herein in their entireties to the full extent permitted by law.

Claims

What is claimed is:

1. An apparatus for toolless electrolytic deburring a metal workpiece, the apparatus comprising:

a) an electrical power supply having an anode and a cathode, the electrical power supply being adapted to selectively supply a DC current;

b) a reservoir for containing a quantity of an electrolyte;

c) a flexible hose having a nozzle, the nozzle being selectively movable with respect to the workpiece during the electrolytic deburring of the workpiece;

d) a pump in fluid communication with the hose, the pump adapted to move the electrolyte from the reservoir through the nozzle;

e) a first electrical lead having a first end electrically connected to the cathode and a second end for electrically connecting the cathode to the electrolyte; and

f) a second electrical lead having a first end electrically connected to the anode and a second end for electrically connecting the anode to the workpiece;

wherein during the electrolytic deburring of the workpiece, the pump moves a portion of the quantity of the electrolyte from the reservoir through the hose and nozzle to form a stream, the first electrical lead second end electrically connects the stream to the cathode, the nozzle selectively directs the stream at the workpiece, the stream impinges the workpiece, the second electrical lead second end electrically connects the workpiece to the anode, and the DC current flows between the anode and the cathode through the workpiece.

2. The apparatus of claim 1, further comprising a filter adapted to remove

:e.

3. The apparatus of claim 1 , further comprising an enclosure having: a) a window through which an operator can view the workpiece during the electrolytic dehurring of the workpiece; and

b) a glove for receiving the operator's first hand, the glove having a gripping area and being adapted to permit the operator to manipulate during the electrolytic deburring of the workpiece at least one selected from the group consisting of the workpiece, the second electrical lead, and the nozzle.

4. The apparatus of claim 3, wherein the second lead second end is electrically connected to the gripping area of the glove so that the operator can bring the workpiece into electrical connection with the second lead second end by gripping the workpiece with the gripping area of the glove.

5. The apparatus of claim 4, further comprising a second glove for receiving the operator's second hand, the second glove having a gripping area adapted to permit the operator to manipulate during the electrolytic deburring of the workpiece at least one selected from the group consisting of the workpiece, the second electrical lead, and the nozzle.

6. The apparatus of claim 3, further comprising at least one of staging area for receiving the workpiece prior to electrolytic deburring and a post-deburring handling area for receiving the workpiece after the electrolytic deburring of the workpiece.

7. The apparatus of claim 6, wherein the enclosure has a work area for electrolytic deburring the workpiece and at least one door selectively separating the work area from at least one of the staging area and the post-deburring handling area.

8. The apparatus of claim 3, wherein the enclosure further comprises a magnifying lens adapted to allow the operator to inspect the workpiece.

9. The apparatus of claim 1, further comprising a foot switch for controlling at least one selected from the the group consisting of the pump and the electrical power supply.

10. The apparatus of claim 1, further comprising a valve adapted to control at least one selected from the group consisting of the flow of the stream from the nozzle and the spray pattern of the stream from the nozzle.

11. The apparatus of claim 10, wherein the valve is incorporated into nozzle.

12. The apparatus of claim 1, further comprising a gas jet, the gas jet being selectively movable with respect to the workpiece and adapted for blowing electrolyte off of a surface of the workpiece.

13. The apparatus of claim 12, wherein the gas jet comprises at least one selected from the group consisting of air, nitrogen, argon, and combinations thereof.

14. The apparatus of claim 12, wherein the nozzle is adapted to emit the gas jet.

15. The apparatus of claim 1, wherein the electrical power supply is adapted to selectively supply a pulsed DC current.

16. A method for toolless electrolytic deburring a metal workpiece, the method comprising the steps of:

a) providing an electrical power supply having an anode and a cathode, the electrical power supply being adapted to selectively supply a DC current;

b) electrically connecting the workpiece to the anode; c) pumping an electrolyte stream through a flexible hose to exit a nozzle, wherein the nozzle is attached to the hose and the stream is electrically connected to the cathode;

d) selectively manipulating the nozzle to controllably impinge the stream upon the workpiece;

e) operating the power supply to flow a DC current between the anode and the cathode through the workpiece; and

f) continuing steps (c) through (e) until the desired level of electrolytic

17. The method of claim 1, further including the step of filtering the electrolyte to remove contaminants.

18. The method of claim 16, further comprising the step of performing steps (c) through (e) in an enclosure, the enclosure having

a) a window through which an operator can view the workpiece during the performance of steps (c) through (e); and

b) a glove for receiving the operator's first hand, the glove having a gripping area and being adapted to permit the operator to manipulate during steps (c) through (e) at least one selected from the group consisting of the workpiece, a lead electrically connected to the anode, and the nozzle.

19. The method of claim 18, further comprising the step of the operator using the glove to manipulate during steps (d) through (f) at least one selected from the group consisting of the workpiece, the lead, and the nozzle.

20. The method of claim 18, wherein a portion of the gripping area of the glove is electrically connected to the anode and step (b) is performed by the operator gripping the workpiece with the gripping area of the glove.

21. The method of claim 18, wherein the enclosure further comprises a second glove and further comprising the step of using the second glove to manipulate during steps (c) through (e) at least one selected from the group consisting of the workpiece and the nozzle.

22. The method of claim 16, further comprising the step of using a valve to control at least one selected from the group consisting of the flow of the stream from the nozzle and the spray pattern of the stream from the nozzle.

23. The method of claim 16, wherein step (d) includes moving at least one selected from the group consisting of the nozzle and the workpiece to change the distance between the nozzle and the workpiece.

24. The method of claim 16, wherein step (d) includes moving at least one selected from the group consisting of the nozzle and the workpiece to impinge the stream upon more than one area of the workpiece.

25. The method of claim 16, further comprising the step of using a gas jet to blow electrolyte off of a surface of the workpiece.

26. The method of claim 25, further comprising the step of selecting the gas jet to comprise at least one selected from the group consisting of air, nitrogen, argon, and combinations thereof.

27. The method of claim 16, wherein the DC current in step (e) is pulsed.