An electrochemical machining system comprises a component having a passage, the passage has an opening and an internal surface formed along the passage, a conductive wire has insulation covering portions of the conductive wire forming gaps having exposed wire; the conductive wire is inserted in the passage; a power source is coupled to the component and the conductive wire forms an electrical circuit, wherein the component comprises an anode and the conductive wire comprises a cathode; and an electrolyte within the passage contacting the internal surface and the exposed wire, wherein the electrolyte comprises a charge-carrying liquid configured to complete the electrical circuit between the cathode and anode.

An electrochemical machining system comprises a component having a passage, the passage has an opening and an internal surface formed along the passage, a conductive wire has insulation covering portions of the conductive wire forming gaps having exposed wire; the conductive wire is inserted in the passage; a power source is coupled to the component and the conductive wire forms an electrical circuit, wherein the component comprises an anode and the conductive wire comprises a cathode; and an electrolyte within the passage contacting the internal surface and the exposed wire, wherein the electrolyte comprises a charge-carrying liquid configured to complete the electrical circuit between the cathode and anode.

A method of detecting the state of a gap between an electrode and a workpiece in electrical discharge machining (EDM) equipment, the method including the steps of: prior to generating an electrical discharge to remove material from the workpiece, applying a low energy checking pulse across the gap during a checking phase period (T.sub.c); and inferring a short circuit gap state when the gap current exceeds a current threshold (I.sub.T).

A method of detecting the state of a gap between an electrode and a workpiece in electrical discharge machining (EDM) equipment, the method including the steps of: prior to generating an electrical discharge to remove material from the workpiece, applying a low energy checking pulse across the gap during a checking phase period (T.sub.c); and inferring a short circuit gap state when the gap current exceeds a current threshold (I.sub.T).

A control device includes a speed setting unit configured to set a relative movement speed of a wire electrode with respect to a workpiece depending on the average of gap voltage per unit time, i.e., average gap voltage, and set the relative movement speed so as to move the wire electrode backward when the average gap voltage is less than a threshold, and a map compensation unit configured to change the threshold from a first threshold that is set when the amount of change in the average gap voltage is lower than a predetermined variation, to a second threshold that is greater than the first threshold, when the average gap voltage has changed in a decreasing direction and the amount of change in the average gap voltage becomes equal to or greater than the predetermined variation.

A control device includes a speed setting unit configured to set a relative movement speed of a wire electrode with respect to a workpiece depending on the average of gap voltage per unit time, i.e., average gap voltage, and set the relative movement speed so as to move the wire electrode backward when the average gap voltage is less than a threshold, and a map compensation unit configured to change the threshold from a first threshold that is set when the amount of change in the average gap voltage is lower than a predetermined variation, to a second threshold that is greater than the first threshold, when the average gap voltage has changed in a decreasing direction and the amount of change in the average gap voltage becomes equal to or greater than the predetermined variation.

A wire electrical discharge machine comprises: an average inter-electrode voltage calculation unit that calculates an average inter-electrode voltage between electrodes; a correction unit that calculates a corrected average inter-electrode voltage, in accordance with a machining speed of a wire electrode with respect to a workpiece; and a motor control unit that makes a dimension between the electrodes during machining constant by controlling an X-axis motor and a Y-axis motor on the basis of the corrected average inter-electrode voltage. The correction unit calculates the corrected average inter-electrode voltage, on the basis of a formula with the average inter-electrode voltage as a numerator, and a value obtained by multiplying a coefficient by the machining speed as a denominator.

A wire electrical discharge machine comprises: an average inter-electrode voltage calculation unit that calculates an average inter-electrode voltage between electrodes; a correction unit that calculates a corrected average inter-electrode voltage, in accordance with a machining speed of a wire electrode with respect to a workpiece; and a motor control unit that makes a dimension between the electrodes during machining constant by controlling an X-axis motor and a Y-axis motor on the basis of the corrected average inter-electrode voltage. The correction unit calculates the corrected average inter-electrode voltage, on the basis of a formula with the average inter-electrode voltage as a numerator, and a value obtained by multiplying a coefficient by the machining speed as a denominator.

Provided is an electrochemical machining apparatus, which includes an electrode (3) that form of a shape which a tube shape is extended, including a flexible conductive material, and is which an electrolyte (W) circulates from a base end side (3b) thereof toward a distal end side (3a) thereof, a current supply unit (6) that causes electric current to flow with respect to the electrode (3) in an extending direction (direction running the Y direction) in which the electrode (3) extends, and a magnetic field generation unit (7) that includes at least one pair of magnets (9) which are disposed to face the electrodes (3) a direction and apply a magnetic field in a direction (X direction) intersecting the extending direction with respect to the electrodes (3).

Provided is an electrochemical machining apparatus, which includes an electrode (3) that form of a shape which a tube shape is extended, including a flexible conductive material, and is which an electrolyte (W) circulates from a base end side (3b) thereof toward a distal end side (3a) thereof, a current supply unit (6) that causes electric current to flow with respect to the electrode (3) in an extending direction (direction running the Y direction) in which the electrode (3) extends, and a magnetic field generation unit (7) that includes at least one pair of magnets (9) which are disposed to face the electrodes (3) a direction and apply a magnetic field in a direction (X direction) intersecting the extending direction with respect to the electrodes (3).