The present method for machining a part includes wire electro-discharge machining the part to create a recast layer, and then removing a zinc content of the recast layer without substantially altering the remainder of the initial composition make-up of the recast layer. The final composition make-up of the recast layer is substantially identical to the initial composition make-up except for the removed zinc content.

The present method for machining a part includes wire electro-discharge machining the part to create a recast layer, and then removing a zinc content of the recast layer without substantially altering the remainder of the initial composition make-up of the recast layer. The final composition make-up of the recast layer is substantially identical to the initial composition make-up except for the removed zinc content.

In the present invention, when performing electrical discharge machining on a workpiece via an electrical discharge machine that has an electrode holder and an electrode guide, a workpiece model and an electrode-guide model are generated in advance, an interference-start position at which the electrode-guide model starts interfering with the workpiece model when the electrode-guide model is moved towards the workpiece model along an axis line (CLa) is calculated, and a position obtained by moving the electrode-guide model a prescribed distance away from the workpiece model, starting at the interference-start position, is set as an electrode-guide position. With the electrode guide positioned at the electrode-guide position, the electrode holder is moved downwards in order to move an electrode downwards toward the workpiece surface, and electrical discharge machining is performed on the workpiece.

In the present invention, when performing electrical discharge machining on a workpiece via an electrical discharge machine that has an electrode holder and an electrode guide, a workpiece model and an electrode-guide model are generated in advance, an interference-start position at which the electrode-guide model starts interfering with the workpiece model when the electrode-guide model is moved towards the workpiece model along an axis line (CLa) is calculated, and a position obtained by moving the electrode-guide model a prescribed distance away from the workpiece model, starting at the interference-start position, is set as an electrode-guide position. With the electrode guide positioned at the electrode-guide position, the electrode holder is moved downwards in order to move an electrode downwards toward the workpiece surface, and electrical discharge machining is performed on the workpiece.

An additive manufactured workpiece includes one or more cavities having an inner surface. A dielectric interface is formed in the cavity, and conforms to the inner surface. The additive manufactured workpiece further includes an in-situ electrode in the cavities. The dielectric interface is interposed between the in-situ electrode and the inner surface of the workpiece.

An additive manufactured workpiece includes one or more cavities having an inner surface. A dielectric interface is formed in the cavity, and conforms to the inner surface. The additive manufactured workpiece further includes an in-situ electrode in the cavities. The dielectric interface is interposed between the in-situ electrode and the inner surface of the workpiece.

A method of improving an internal surface topography of a manufactured workpiece includes filling a workpiece with an electrically conductive magnetorheological (MR) fluid. The workpiece includes at least one internal feature having an inner surface with at least one irregularity. The method further includes converting the MR fluid into a rigid MR material, applying a voltage to the rigid MR material, and ablating the inner surface in response to the voltage to remove the at least one irregularity.

A method of improving an internal surface topography of a manufactured workpiece includes filling a workpiece with an electrically conductive magnetorheological (MR) fluid. The workpiece includes at least one internal feature having an inner surface with at least one irregularity. The method further includes converting the MR fluid into a rigid MR material, applying a voltage to the rigid MR material, and ablating the inner surface in response to the voltage to remove the at least one irregularity.

A wire electric discharge machining apparatus includes upper and lower wire guide units including wire guides configured to position and guide a wire electrode and a jet nozzle configured to supply a jet flow coaxially with the wire electrode, and a core holding pad having a through-hole passing therethrough in an upward/downward direction, and in which a plurality of protrusion sections having an equal distance from upper surfaces thereof to a lower surface of the workpiece are formed. The core holding pad is disposed on the lower wire guide unit such that the core holding pad approaches the lower surface of the workpiece as closely as possible.

A wire electric discharge machining apparatus includes upper and lower wire guide units including wire guides configured to position and guide a wire electrode and a jet nozzle configured to supply a jet flow coaxially with the wire electrode, and a core holding pad having a through-hole passing therethrough in an upward/downward direction, and in which a plurality of protrusion sections having an equal distance from upper surfaces thereof to a lower surface of the workpiece are formed. The core holding pad is disposed on the lower wire guide unit such that the core holding pad approaches the lower surface of the workpiece as closely as possible.