In this study, the authors tried to make holes in a titanium-based superalloy by a completely new machining method called electro-discharge drilling (EDD) using a gas-aided multi-hole rotating tool. Successful machining of the titanium work samples is extremely challenging due to its extreme hardness and stiffness. One of the key challenges facing the EDD operation is the elimination of spark-eroded matters from the electrodes gap. Arcing happens when the trash is collected in the working passage, which adversely affects the performance of the EDD. In this study, an effort has been made to explore an active flushing mechanism that can improve the flushing activity during the EDD process. Computational fluid dynamics analysis suggested that successful internal flushing by multi-hole rotating tools might result in the efficient removal of the molten material from the electrodes gap. In addition, in this study, a comparative assessment of the EDD with the gas-aided multi-hole rotary electrode and the EDD with the stationary solid tool was carried out taking into account significant EDD responses. Besides, it was observed from the investigation that increased material removal rate and reduced EWR as well as surface roughness were acquired in the EDD with a gas-aided multi-hole rotating electrode in comparison with the EDD with a conventional stationary solid electrode. Basic analysis of surface morphology indicates that the development of recast layers and surface cracks is not very likely to occur on specimens machined with a gas-aided multi-hole rotating electrode in comparison with a workpiece machined with a conventional stationary solid electrode. The results indicate that the use of pressured argon gas in EDD with a gas-assisted multi-hole rotating electrode has a beneficial effect on the execution of the procedure.

在这项研究中，作者试图使用气体辅助多孔旋转工具，通过一种称为电火花钻孔（EDD）的全新加工方法在钛基高温合金中打孔。由于钛加工样品的极高硬度和刚度，因此成功进行机加工极具挑战性。EDD操作面临的主要挑战之一是消除电极间隙中的火花腐蚀物质。当在工作通道中收集垃圾时会产生电弧，这会对EDD的性能产生不利影响。在这项研究中，已努力探索一种主动冲洗机制，该机制可以改善EDD过程中的冲洗活动。计算流体动力学分析表明，使用多孔旋转工具成功进行内部冲洗可能会导致熔融材料从电极间隙中有效去除。此外，在这项研究中，考虑到重要的EDD响应，对使用气体辅助多孔旋转电极的EDD和使用固定固体工具的EDD进行了比较评估。此外，从研究中观察到，与具有常规固定固体电极的EDD相比，具有气体辅助多孔旋转电极的EDD获得了更高的材料去除率和降低的EWR以及表面粗糙度。表面形态的基本分析表明，与用传统的固定式固体电极加工的工件相比，用气体辅助多孔旋转电极加工的样品不太可能发生重铸层和表面裂纹的发展。结果表明，在带有气体辅助多孔旋转电极的EDD中使用加压氩气对程序的执行具有有益效果。