Abstract: A microhole electric discharge machining apparatus that forms a conical inverse-tapered hole on a workpiece by a thin wire electrode, includes, an electrode holder that holds an upper part of the thin wire electrode and feeds a lower part of the thin wire electrode downward to stretch the lower part to the workpiece by rotating the thin wire electrode; a first guide member that is arranged near the workpiece upper surface and is provided with a first guide hole through which the thin wire electrode is penetrated on a hole-machining axis; a second guide member that is arranged between the first guide member and the electrode holder and is provided with a second guide hole through which the thin wire electrode is penetrated at a position eccentric from the hole-machining axis; and a swivel driving unit that circularly swivels the second guide member around the hole-machining axis.

Abstract: A material piece scooping device, which extracts a material piece from a surface of an object to be scooped by cutting electric discharges between an electric discharge electrode and the object to be scooped, includes a rotation drive section 40, an arm portion 30 driven by the rotation drive section to rotate around a rotational axis X, an electrode holder 20 supported by the arm portion, and an electric discharge electrode 10 detachably mounted on the electrode holder. A sliding section for sliding the arm portion in a direction perpendicular to the rotational axis and an arm length adjusting section for adjusting a length of the arm portion from the rotational axis thereof are provided, so as to adjust a trajectory of the electric discharge electrode as the arm portion rotates. The material piece can be scooped from the object along a line of the trajectory gnawing into the object.

Abstract: An electrode wire for discharging working; the electrode wire being formed by an alloy of copper and zinc; in manufacturing process, passing the alloy with a form of fluid through a furnace so as to form with a desire shape; wherein by siphon theory, a metal tube serves to suck the alloy; the process is made continuously in a predetermined temperature; then the alloy being performed with cold-extension and annealing repeatedly so as to form with electrode wire which is stable, uniform and has a preferred electric conductivity. in the alloy of copper and zinc, the content of zinc is about 35˜45%. An extension strength of the wire is between 650 to 1150 MPa.

Abstract: An electric discharge machine template fixture (40) suitable for EDM redressing operations, the fixture (40) comprising a body (42) capable of holding a template (50) and capable of rotating the template (50) about its central axis (58) for consecutive redressing operations.

Abstract: An electrode for electric discharge surface treatment, in which a pulse-like electric discharge is caused between the electrode and a work in a dielectric fluid or an atmosphere, and in which a coat of an electrode material or a substance that is generated by a reaction of the electrode material due to an electric discharge energy is formed on a surface of the work, is a molded powder that is formed by molding a material powder including a metallic powder, a metallic compound powder, and a conductive ceramic powder. A powder solid that is formed as a result of coagulation of the material powder, and that is included in the molded powder has a diameter shorter than a distance between the electrode and the work.

Abstract: Spark-erosion machining method and machine implementing a machining gap, a process regulator, a numerical control system, a Nominal Trajectory. The latter describes the movement of the tool electrode relative to the part as it ought to proceed if no disturbance were to occur during the machining. Information contained in the Nominal Trajectory is used to define at least two control vectors Vg, Vp which orient, within the coordinate system XYZ, two independent regulation movements. The first, or Gap Vector Vg, defines the direction in which a first regulation movement of the axes of the machine must be performed to maintain the removal of material. The second, or Position Vector Vp, defines the direction in which a second regulation movement of the axes of the machining machine must be performed to correct a tool electrode position error. The respective amplitudes of the regulation movements are calculated in real time by the process regulator.

Abstract: An electrode for machining a pattern in a workpiece has a conductive body with a lattice of closed cells and a plurality of open cells. The open cells are positioned at an edge of the lattice of closed cells. The closed cells are defined by interconnected webs, and the open cells are defined by fins extending from the interconnected webs. A thickness of the fins is less than a thickness of the webs. In use, the electrode is positioned at a plurality of locations on the workpiece, such that a position of the fins of the electrode at each location overlaps a position of the fins of the electrode at an adjacent location. The pattern is formed at each of the plurality of locations by passing electrical charges repeatedly between the electrode and the workpiece and advancing the electrode into the workpiece.

Abstract: An electrical discharge machining (EDM) tool and method for removing tack welds on a component in a reactor pressure vessel are disclosed. The tool may include a motor, a housing which engages the component having tack welds, an electrode, positioned in the housing, a first plate, and a second plate attached to the electrode. The second plate actuates to align the electrode to the tack weld, and the electrode is discharged to remove the tack welds from the component.

Abstract: An electrode tube holding apparatus is mounted to an electric discharge machine (EDM). The holding apparatus is slidable upward and downward along with the spindle of the EDM and maintained within the midsection of an electrode tube for reducing the deformation of the electrode tube during its movement.

Abstract: An electrode wire for wire electric discharge machining includes a binary alloy of copper and zinc. The electrode wire is manufactured by hot-extruding an alloy including copper and zinc at a predetermined ratio and then cold-drawing and annealing the hot-extruded alloy, and ? phase crystals and ?? phase crystals uniformly exist.

Abstract: An electrical discharge assembly for processing a workpiece having a cooling passage with first and second portions includes a first electrode having a first shape for machining the first portion of the cooling passage and a second electrode having a second shape for machining the second portion of the cooling passage. In a method for repairing cooling passages in a workpiece, a first electrode having a first shape is positioned in a cooling passage. The first electrode is electrically powered to machine a first portion of the cooling passage. A second electrode having a second shape is positioned in the cooling passage. The second electrode is electrically powered to machine a second portion of the cooling passage.

Abstract: In accordance with one embodiment of the present disclosure, an electrical discharge machine is provided comprising an EDM electrode, an electrode holder, and an electrode guide. The electrode guide comprises an internal passage profile that transitions along the machining axis from a substantially circular cross section comprising a diameter d2 to an apexed cross section. The EDM electrode extends from the electrode holder through the electrode entrance aperture of the electrode guide and out of the electrode exit aperture of the electrode guide. The apexed cross section of the electrode guide is aligned relative to the circular cross section of the electrode guide such that apexes of the electrode exit aperture lie outside of a circumferential portion of the circular cross section. A restricted circumferential portion defined by the apexed cross section comprises a diameter that is greater than the effective electrode diameter. Additional embodiments are disclosed and claimed.

Abstract: An EDM die sinking device includes a tank for holding a fluid, and at least one electrode in the tank having a shape for imparting to a first portion of a workpiece. A workpiece holder positions the workpiece at least partially immersed in the fluid and alternately moves the workpiece between an inoperable position and a first operable position of the first electrode at which electric discharge machining occurs on the first portion. A pulse generator creates an electric discharge between the first portion and the first electrode to remove material from the first portion in response to the workpiece being in the first operable position. Movement of the workpiece from the electrode flushes particle containing fluid away from the workpiece and the electrode. A segmented electrode includes a separate pulse generator for each segment may also be employed.

Abstract: A metal coating removing apparatus (1) includes a first electrode (13) arranged so as to be opposed to a metal coating (101) as an object to be removed, a second electrode 14 arranged so as to be opposed to the metal coating (101) at a predetermined distance from the first electrode (13), and a pulse power generator (11), for example, that functions as a discharge energy supply portion. The pulse power generator (11) supplies discharge energy between the first electrode (13) and the second electrode (14) so as to allow discharging to occur between the first electrode (13) and the second electrode (14). By allowing discharging to occur between the first electrode (13) and the second electrode (14), the metal coating (101) can be removed.

Abstract: An electrode for electric discharge surface treatment is a green compact formed by molding a metal powder, a metal compound powder, or a ceramic powder, and is used for electric discharge surface treatment in which an electric discharge is generated between the electrode and a work in dielectric fluid or air to form by the electric discharge energy on a surface of the work a coat of a material of the electrode or of a substance resulting from reaction of the material due to the electric discharge energy. The material of the electrode includes a material not desired to be carbonized and a material desired to be melted, and a particle diameter of the material not desired to be carbonized is larger than a particle diameter of the material desired to be melted.

Abstract: A method of securing an workpiece for machining the trailing edge. The workpiece has a platform from which extends an airfoil, the airfoil including a leading edge and a trailing edge, and a pressure side and a suction side. A fixture with at least one locating datum that relates to the platform and at least one locating datum that relates to the leading edge is provided. The fixture does not contact the trailing edge of the workpiece. The workpiece is positioned so that the platform is against the related locating datum and the leading edge is against the related locating datum. The workpiece is secured within the fixture, and the trailing edge of the workpiece is machined.

Abstract: A forming 7 die is filled with a powder (11) of electrode material, the powder (11) of electrode material filled in the forming die is compressed to form a porous powder compact (27), the porous powder compact (27) is set in place in a chamber (25) of a heat-treating furnace (23), the chamber (25) is supplied with inert gas or hydrogen gas, and inert gas or hydrogen gas is heated by heaters (39) in the heat-treating furnace (23) and blown toward the powder compact (27), as blows circulating in the chamber (25), whereby the powder compact is heated with heat of convection flows of inert gas or hydrogen gas, or mixed gas containing inert gas as principal component and hydrogen gas, so the electrode material of the powder compact is sintered.

Abstract: An electrode wire for wire electrodischarge machining includes a core made of copper or copper alloy, a pure zinc layer formed by hot-dip galvanizing the core, and a relatively thin copper-zinc alloy layer formed by mutual thermal diffusion across the interface between the pure zinc layer and the core and having a zinc concentration gradient. The electrode wire is not cracked during its production. The thickness of the copper-zinc alloy layer, the gradient of zinc concentration, and the thickness of the outermost pure zinc layer can be controlled by selecting the dipping time and the temperature of the hot-dip galvanizing bath as appropriate. By blowing a non-oxidizing gas from a bath surface zinc purifying and wiping device disposed above the bath surface through which the core emerges from the hot-dip galvanizing bath, the pure zinc bath surface is kept exposed and runs and uneven thickness of the galvanizing layer are prevented.

Abstract: A Tandem-type micro electro-discharge machining (EDM) apparatus comprises a EDM machining stage, a gradation twin-wire EDM device, an electrode tool, a workpiece, and a resistor-capacitor (RC) EDM circuit. The gradation twin-wire EDM device further comprises a wire supply reel unit, a wire take-up reel unit, a stepped insulating roller, a twin-wire conductor unit, and a discharge circuit unit. With the design of the gradation twin-wire EDM device, only one single EDM procedure is needed to simultaneously perform rough EDM and finish EDM processes together on the electrode tool to form a required micro electrode tool, which can be immediately used to perform micro-hole EDM or scanning EDM on the workpiece. Therefore, the Tandem-micro EDM apparatus of the present invention can be functioned automatically to achieve mass production of micro holes EDM and reduce machining time and improve machining efficiency and product's quality.

Abstract: Enhanced electrode discharge machining properties of an electrode wire are achieved when the electrode wire comprises a coil, a covering layer formed on a periphery of the coil, and grains formed on the covering layer. The grains comprise a copper-zinc alloy including about 0.01 to 0.5 weight % of at least one additive element selected from the group consisting of aluminum, tin, magnesium, lanthanum, cerium, nickel, manganese, titanium, and zirconium.

Abstract: The hand-held electro-discharge machining fastener removal device of this invention brings an EDM electrode and its supporting ground pin and dielectric fluid structure to a fastener in a workpiece, such as an aircraft fuselage. The hand-held device brings the dielectric fluid, power supply, and control system structure to the fastener in a compact tool to permit EDM machining to be brought to large structures.

Abstract: An EDM spindle assembly is provided comprising a pull stud, an electrode holder, a fluid seal, and a seal holder. The electrode holder comprises a tail end, a nose end, and an electrode accommodating passage. A counter bore comprising a threaded inside diameter is formed in the tail end of the electrode holder. The seal holder comprises a threaded outside diameter, a tail end, a nose end, and an electrode accommodating passage. The seal accommodating space is formed in the tail end of the seal holder. The threaded outside diameter of the seal holder is suitable for threaded engagement with the threaded inside diameter of the counter bore. The pull stud comprises a threaded outside diameter, a tail end, a nose end, and an electrode accommodating passage. The threaded outside diameter of the pull stud is suitable for threaded engagement with the threaded inside diameter of the counter bore.

Abstract: The invention concerns an electrode wire comprising an unalloyed copper core coated with a diffused zinc alloy coating layer, whereof the thickness is more than 10% of the wire diameter. The coating layer is optionally plated with a thin zinc, copper, nickel, silver or gold surface contact film. Such a wire achieves higher electrical discharge machining speed.

Abstract: A method of wire electrical discharge machining comprising applying a pulsed voltage between a tool electrode and a workpiece which are physically separated by a working gap, the tool electrode being in the form of a wire with an electrically conductive core and an external surface embedded with an electrically non-conductive abrasive material.

Abstract: A material piece scooping device, which extracts a material piece from a surface of an object to be scooped by generating electric discharge between an electric discharge electrode and the object to be scooped, includes a rotation drive section 40, an arm portion 30 driven by the rotation drive section to rotate around a rotational axis X, an electrode holder 20 supported by the arm portion, and an electric discharge electrode 10 detachably mounted on the electrode holder. A sliding section for sliding the arm portion in a direction perpendicular to the rotational axis and an arm length adjusting section for adjusting a length of the arm portion from the rotational axis thereof are provided, so as to adjust a trajectory of the electric discharge electrode as the arm portion rotates. The material piece can be scooped from the object along a line of the trajectory gnawing into the object.

Abstract: A method of manufacturing an electrode for electrical-discharge surface treatment includes kneading a first electrode material composed of at least one of metal powder and insulating powder and a second electrode material composed of conductive organic bonding agent in which a conductive resin is dissolved or dispersed in a solvent, to fabricate a slurry; molding the slurry, to form a compact; and desiccating the compact at a temperature below a thermal decomposition initiating temperature at which a thermal decomposition of the conductive organic bonding agent starts.

Abstract: An electrical discharge machining electrode includes a body and one or more shaped teeth. The one or more shaped teeth of the body have a diffuser section and a metering section in electrical communication therewith. The body and the teeth may be formed by a process of photochemically etching a substrate made from an electrically conductive material.

Abstract: A chuck device for electrical discharge machine includes a mold fixed to the machine and a connector connected to the discharge head. The connector has a connection rod having a neck and the connection rod is connected to the mold. A plurality of protrusions extend from the top of the connector and each protrusion has a groove which is defined by two facing inclined surfaces. The mold has a plurality of positioning bars fixed to an underside thereof and each positioning bar has a taper-shaped body with two inclined sides. The positioning bars are engaged with the grooves and the two inclined sides of the positioning bar are in contact with the inclined surfaces of the groove. A distance is defined between the flanges and a top of the protrusion.

Abstract: A method of machining a cathode used in an electron gun. The method includes steps of placing an object to be machined, which is a material of the cathode, and a machining electrode in an electrically insulating oil; applying a discharge current to the machining electrode; and machining the object to be machined to have a shape corresponding to the shape of the machining electrode by means of electric discharge machining of the machining electrode. The machining electrode includes a disk, recesses formed on a front surface of the disk, a protrusion provided on a back surface of the disk, and a hole for mounting a lead wire for applying discharge current to the machining electrode. Bumps corresponding to the shape of the recesses of the machining electrode are formed on the object to be machined by means of the electric discharge machining.

Abstract: An electrode for EDM.

Abstract: The invention relates to an electrode arrangement for the electrical discharge machining of an electrically non-conductive material, which comprises a first component for removing the electrically non-conductive material and a second component for depositing an electrically conductive substance on the electrically non-conductive material.

Abstract: A multi-function machine includes an electrode having a passage, a power supply device electrically connected with the two opposite terminals thereof to the electrode and the workpiece to be processed, a feeder for selectively feeding a gas or fluid to the passage of the electrode, a first laser beam and a second laser beam respectively projected through the passage of the electrode onto the workpiece, and a detection control device for receiving the reflective light wave of the second laser beam reflected by the workpiece.

Abstract: A welding guide nozzle for precision weld positioning of a feedstock material in a welding system. The welding guide nozzle includes a nozzle structure defining a substantially cylindrical holding apparatus that tapers at one end to define a nozzle tip. The holding apparatus and the nozzle tip include concentric bores defined therein. An erosion resistant rod is disposed within the bore defined in the nozzle tip. The erosion resistant rod includes a bore defined therein into with the weld feedstock material is disposed. The erosion resistant material is formed of a high heat resistive material thereby permitting positioning in close proximity to a heat source.

Abstract: A wall element having at least one cooling channel formed therein, the wall element presenting an inside surface and an outside surface, the channel comprising a hole and a diffusion portion, the hole opening out at one end in the inside surface, and at the other end in a diffusion portion where it forms an orifice, the diffusion portion flaring around said orifice and being defined by a bottom wall and a side margin. Said bottom wall presents a first plane portion into which the hole opens out, and a second plane portion situated in front of the first plane portion, said first and second plane portions being inclined in the thickness of the wall. The oriented angle of inclination of said first plane portion is less than the positive oriented angle of inclination of said second plane portion.

Abstract: A microshaft forming method and apparatus for forming a microshaft without requiring high level of stillness required by conventional methods. The microshaft forming apparatus comprises an elongated electrode (1) to be formed into a microshaft, a forming plate (3) for forming the electrode (1), electrode rotating means for rotating the electrode (1) around the length direction (1a) of the electrode (1), a discharge machining power supply (5) for applying a voltage between the electrode (1) and the forming plate (3) to cause discharge between the electrode (1) and the forming plate (3), and electrode moving means for traversing the electrode (1) rotated by the electrode rotating means across the forming plate (3) from the side edge surface (3a) of the forming plate (3).

Abstract: A pulsed discharge is generated between tip ends of a rotating member such as a blade and a discharge electrode including a hard material such as cBN in dielectric liquid or gas by a power supply for discharge to melt the discharge electrode, and a part of the discharge electrode is attached to the tip end of the rotating member to form an abrasive coating film including the hard materials such as cBN.

Abstract: An electric discharge machining apparatus includes a guide electrode that is tubular and receives a small-diameter wire electrode for electric discharge machining. The small-diameter wire electrode can freely slide within the guide electrode. A guide electrode holder holds the guide electrode at a specified position. Pressurized fluid is supplied into the guide electrode to feed the small-diameter wire electrode from the guide electrode. A small-diameter wire electrode holder automatically releases and grasps the small-diameter wire electrode in response to starting and stopping of the pressurized fluid supply, respectively.

Abstract: In a molding die machining electrode, slit grooves of a molding die are machined with a slit groove forming part having a substantially circular outer circumference by ranging hexagonal erected wall parts in a row; while the inner circumference of a slit groove forming part overlaps with the erected wall parts in the outer circumference of the slit groove forming part, the outside slit grooves are machined with the slit groove forming part having a substantially circular outer circumference. The further outside slit grooves are machined with the slit groove forming part of the third electrode. A plurality of the slit groove forming parts are radially divided and overlapping portions between the plurality of the slit groove forming parts are formed substantially coaxially with a molded body. The areas of the slit groove forming parts are designed to nearly similar values, suppressing the difference in wear of the electrodes.

Abstract: A wire electric discharge machining apparatus includes guide rollers, one electrode wire that is wrapped around each of the guide rollers to form cut wire portions spaced from one another between a pair of the guide rollers. A processing power supply feeds electric power to the individual cut wire portions through a power feed element, and a high frequency insulator has wound coils which are formed of the electrode wire and located between adjacent ones of the cut wire portions 2a, respectively, and cores which close magnetic circuits of the individual coils, respectively, and are magnetically insulated from one another. The power feed element is arranged between the individual cut wire portions and the individual coils, and the individual cut wire portions are insulated from one another by the individual coils at high frequencies. As a result, it becomes possible to impress voltages on the individual cut wire portions independently, so discharges can be generated in a simultaneous and parallel manner.

Abstract: A rough machining method for machining a channel in a workpiece includes the steps of: provide a power supply to energize one of a workpiece and an electrode as an anode and the other as a cathode; advance the electrode into the workpiece from a first start point to travel a first toolpath, so as to generate a first annular groove with a first core connecting with the workpiece; advance the electrode into the workpiece from a second start point to travel a second toolpath, so as to generate a second annular groove with a second core connecting with the workpiece, wherein the second annular groove intersects with the first annular groove and the first and the second cores are at least partially broken and disconnected with the workpiece upon intersecting of the first and the second annular grooves; and circulating a cutting fluid cross a working gap between a working face of the electrode and the workpiece.

Abstract: Systems and methods presented herein provide for the control of electrical energy discharge from an electrode. In this regard, a sensor detects electrical energy discharged from the electrode and generates an electronic signal representative of a detected electrical energy discharge. Such a sensor may detect an electric field and/or light from the electrical energy discharge. The sensor may generate the electronic signal therefrom for subsequent processing. Accordingly, the system also includes a controller communicatively coupled to the sensor to determine a spurious discharge of the electrical energy discharge from the electrode. The controller processes the electronic signal to control at least one characteristic (e.g., voltage) of the electrical energy provided to the electrode. The controller may change a voltage of the electrical energy to the electrode in response to determining a spurious discharge of the electrical energy discharged from the electrode.

Abstract: A method is provided for milling a thermal barrier coated metal part. This method includes selectively removing a portion of a ceramic coating using a mechanical cutting tool, thereby forming a counterbore, and machining the metal part through the counterbore. A drilling head for drilling thermal barrier coated metal parts is also provided. The drilling head comprises a mechanical cutting tool, which is operable to mill through ceramic, and an electrode for electrical discharge machining. The electrode may be used to mill the metal part, and may be interchangeable with the mechanical cutting tool.

Abstract: A system, method, and computer program for designing an electrode for electric discharge machining, comprising identifying a cavity in a three-dimensional design; calculating a direct negative boolean of said cavity to define a general form for an electrode; determining an orbit path for said electrode, wherein said orbit path has a plurality of vertices corresponding to a plurality of instances with said three-dimensional design; subtracting a plurality of instances from said general form for said electrode whereby an orbit gap is removed from said general form electrode; and applying a constant face offset to said general form for said electrode having said orbit gap and appropriate means and computer-readable instructions.

Abstract: A method of machining a pattern at a plurality of locations in a workpiece includes positioning a shaped electrode including the pattern at the plurality of locations in a sequence. In some embodiments, the sequence is random. The method further includes forming the pattern at each of the plurality of locations by passing electrical charges repeatedly between the shaped electrode and the workpiece and advancing the shaped electrode into the workpiece for a fraction of a full depth of the pattern. The method further includes repeating the positioning and forming steps a plurality of times until the full depth of the pattern has been formed at each of the plurality of locations.

Abstract: A device for cleaning a bevel edge of a semiconductor substrate. The device includes a lower electrode assembly that has a top surface and is adapted to support the substrate and an upper electrode assembly that has a bottom surface opposing the top surface. The lower and upper electrode assemblies generate plasma for cleaning the bevel edge of the substrate disposed between the top and bottom surfaces during operation. The device also includes a mechanism for suspending the upper electrode assembly over the lower support and adjusting the tilt angle and horizontal translation of the bottom surface relative to the top surface.

Abstract: Disclosed herein is a compound electrode comprising a first portion comprising graphite; and a second portion comprising a metal; wherein the first portion is in continuous communication with the second portion along a length of the compound electrode. Disclosed herein too is a compound electrode comprising a first portion comprising graphite; and a second portion comprising a metal; wherein the first portion is in a tight fit with the second portion along a length of the compound electrode. Disclosed herein is a method comprising creating an electric arc between a compound electrode and a workpiece; wherein the compound electrode comprises a first portion comprising graphite; and a second portion comprising a metal; wherein the first portion is in a tight fit with the second portion along a length of the compound electrode; and removing a portion of the workpiece.

Abstract: A clamping device, having a first and a second coupling part, for the tool of a machine tool. The first coupling part is eccentric and comprises small rails having angular off-sets in relation to each other and limiting surfaces for exactly positioning the second coupling part in the xy plane. The second coupling part comprises lateral faces having elastic lips which rest against the limiting surfaces, a connecting device is used to exactly position the first and the second coupling part in the z plane. The second coupling part consists of a piece having various strength values, ductility values and/or hardness, whereby the areas of the lips have higher strength values, ductility values and/or harnesses than the other areas of the lips and/or areas of the second coupling part.

Abstract: A work station for an electrical discharge machining apparatus, including a first mechanism for retaining a workpiece in a predetermined position, at least one electrode for forming a feature on the workpiece, and a second mechanism for positioning the electrode in a manner that is movable into and out of engagement with a designated portion of the workpiece. A portion of the second mechanism is connected to the first mechanism so as to automatically align the electrode with the designated portion of the workpiece. The second mechanism is configured so that the electrode is electrically insulated from the workpiece.

Abstract: An electric discharge machine and method for carrying out electric discharge machining there within is provided, wherein after an electrode (21) and an electrode guide holder (25) are attached to an electrode holder (23), in advance, which is in turn mounted on a spindle (13), the electrode guide holder (25) is gripped by a gripper arm (29) and moved to a distal end of the electrode (21) so that the machining is carried out while the distal end of the electrode (21) is supported by an electrode guide (61). When the electrode (21) must be replaced due to the exhaustion thereof during the electric discharge machining of a fine hole, the electric discharge machine and method make it possible to assuredly carry out the replacement of the electrode in a short time.

Abstract: A cutting tool assembly using a machined tool operating in a plunge mode of electrical discharge machining to make microreplicated features in a work piece having a complex surface. The microreplicated features can be non-adjacent and can have any geometric configuration and micron-scaled dimensions, as determined by the microstructured features in the tool. The machined work piece can be used as a master tool in order to make microreplicated articles such as optical films, friction control films, plasma display panel molds, or micro-fasteners.