Methods for the electroerosion machining of high-performance metal alloys

A method of machining a work-piece formed of titanium-based material, using a machining apparatus, the method comprising:

• (a) providing an electrode contained within a spindle assembly, in a pre-selected distance and position relative to the work-piece, while electrically powering the electrode and the work-piece with a power supply, wherein the electrode is electrically-conductive;
• (b) circulating a fluid electrolyte through at least two pathways in the machining apparatus, wherein a first pathway comprises an internal conduit within the spindle assembly, and wherein a second pathway comprises an external conduit outside of the spindle assembly and at least partially within a gap between the electrode and the work-piece;
• and
• (c) moving the electrode relative to the work-piece in a plunging motion, and retracting the electrode to permit removal of the titanium-based material from the work-piece using a high-speed electroerosion (HSEE) process,
• wherein a total flushing pressure value of the circulating fluid electrolyte and a rotational speed of the electrode are simultaneously controlled by an automated mechanism when a measured current in the electrode exceeds a threshold current of the electrode, so as to maximize an efficiency of removal of the titanium-based material from the work-piece by reducing formation of a molten metal bridge from debris of the removed titanium-based material in the gap.