A gap detection apparatus for determining in real time the gap required for electrochemical machining gap includes a tooling electrode, a plurality of tool adjusting electrodes, a feedback circuit, a processing feed mechanism for controlling the tooling electrode, a three-dimensional driving mechanism, and an automatic control and measurement system. The tooling electrode includes a plurality of through-holes for receiving tool adjusting electrodes. The three-dimensional driving mechanism is mounted upon the processing feed mechanism, which includes a Z-coordinate feeding portion having a thimble for the feeding of the tool adjusting electrodes. The automatic control and measurement system controls the feed of the processing feed mechanism and the three-dimensional driving mechanism, and establishes the required gap for electrochemical machining.

An electrical discharge machining (EDM) fixture for machining a part includes a support structure fixable onto a work surface, a base plate fixed to the support structure, a toggle clamp positioned on one side of the base plate, and a secondary clamp positioned on an opposite side of the base plate. A plurality of contact points are respectively associated with the toggle clamp and the secondary clamp, and a tool ball is fixed to the base plate.

An electrical discharge machining (EDM) fixture for machining a part includes a support structure fixable onto a work surface, a base plate fixed to the support structure, a toggle clamp positioned on one side of the base plate, and a secondary clamp positioned on an opposite side of the base plate. A plurality of contact points are respectively associated with the toggle clamp and the secondary clamp, and a tool ball is fixed to the base plate.