Abstract: An electrical discharge machine is configured to (i) machine at least a portion of a workpiece through electrical discharge between the workpiece and a first machining electrode aligned by the electrode guide; (ii) generate a dressed machining electrode by engaging a machining electrode aligned by the electrode guide with the electrode dresser; and (iii) machine at least a portion of a workpiece through electrical discharge between the workpiece and the dressed machining electrode. Additional electrical discharge machines and methods of machining are provided.

Abstract: Electrical discharge machines are disclosed that are capable of a relatively wide range of flexibility and range of motion for performing electrical discharge operations. The electrical discharge machine herein can optionally comprise up to, and in excess of six axes of motion to adjust the electrode relative to the workpiece. To effectively remove the swarf that is generated during electroerosion operations, a primary flushing system and an optional auxiliary flushing system are provided. The auxiliary flushing system is used to direct dielectric fluid towards the workpiece external to the electrode. Further, methods of performing high speed electrical discharge machining operations are disclosed, including methods for establishing the zero set conditions that indicate initiation of the electroerosion process based upon a detection of dither on the electrode travel.

Abstract: The present invention provides electrical discharge machines that are capable of a relatively wide range of flexibility and range of motion for performing electrical discharge operations. For example, an electrical discharge machine according to at least one embodiment of the present invention can optionally comprise up to, and in excess of six axes of motion. To effectively remove the swarf that is generated during electroerosion operations, the present invention optionally provides both a primary and an auxiliary flushing system. The auxiliary flushing system is used to direct dielectric fluid towards the workpiece external to the electrode. The present invention also provides methods of performing high speed electrical discharge machining operations including determining the zero set conditions that indicate initiation of the electroerosion process.