Performance improvement of high-speed EDM and ECM combined process by using a helical tube electrode with matched internal and external flushing

Micro-hole fabrication at a high speed and accuracy of machining while maintaining surface quality is challenging. A core difficulty the removal products from extremely narrow gaps. To solve this problem, study proposes an approach that combines high-speed electrical discharge (EDM) with electrochemical (ECM) by using helical tube electrode matched internal external flushing. During drilling, matching flushing clockwise rotation can help remove debris bottom blind hole. ECM, anticlockwise improve flow electrolyte in gap. First, field was simulated to show enhance medium reduce particle concentration Second, series experiments were conducted verify taper hole its wall be improved electrode. Finally, experiment carried out optimize parameters yielded minimum 0.008 460 rpm, pressures 9 MPa 4 MPa, respectively.