A Tube Electrode High-speed Electrochemical Discharge Drilling Method without Recast Layer

The tube electrode high-speed electrochemical discharge drilling (TEECDD) is a hybrid process that combines electrical discharge high-speed drilling and electrochemical machining (ECM). By using a low conductivity salt solution as the working fluid, electrical discharge high-speed drilling takes place mainly in the frontal gap, and the recast layer at the side gap can be removed electrochemically at the same time. The machining voltage and current waveforms were recorded in the experiments. The tool wear performances were compared with pure electrical discharge machining (EDM). The results of removing the recast layer and the machining quality were analysed. Finally, a small hole can be fabricated with low tool wear and almost no recast layer by the hybrid process.