Background: The fabrication of Micro-holes in hard machining materials is always difficult
according to recent patents. The electrochemical drilling process is a good selection for the fabrication
Methods: In this paper, an electrochemical drilling process for fabricating Micro-holes with high efficiency is
introduced, and simulation of the gap electric field and the gap flow field is carried out. Firstly, the model of ultra
short pulse gap electric field is established, the shape change of the anode workpiece surface in the electric
field is analyzed and predicted based on the simulation of the drilling with ultra short pulse voltage. Then, the
numerical simulation of the gap flow field is simulated by CFX with the increase of the electrode rotating
speed. Finally, the simulation results are verified by the experiments.
Results: The removal direction and rate of a point on the surface of the workpiece with ultra short pulse
voltage was derived. The shape change of the anode workpiece surface with ultra short pulse voltage
was simulated. The distribution of water vapor and the velocity vector graph in micro machining was
obtained. A series of Micro-holes was machined successfully, the diameter of the Micro-holes was less
Conclusion: The ultra short pulse voltage can greatly improve the machining localization. The gas film
with good insulation effect around the electrode increases rapidly, which can reduce the taper of the Micro-
holes significantly. The experiment results prove that the micro electrochemical drilling for fabricating
Micro-holes has a huge potential and a widespread application prospect.