Automatic blocked hole identification

A method for hole formation using an electrical discharge machining tool configured to penetrate metal, the method comprising the steps of:

• penetrating the metal using an electrode to form a hole by moving the electrode away from a starting point in a first direction;
• verifying that the hole is complete and open using the electrical discharge machine, the verifying step including the steps of:
• retracting the electrode in a second direction a predetermined distance X;
• probing the hole with the electrode, the probing step including the steps of:
• advancing the electrode in the first direction a distance Y;
• and
• comparing the distance Y to the predetermined distance X after the electrode is stopped;
• and
• determining that the hole is incomplete if the distance Y is equal to or less than the predetermined distance X plus a deadband value.

A method for hole formation using an electrical discharge machining tool that includes an electrode configured to penetrate metal, the method comprising the steps of:

• positioning the electrical discharge machining tool on a component in which a hole is to be formed;
• forming the hole by penetrating the metal using an electrode moving in a first direction, the electrode having a voltage applied thereto;
• monitoring a predetermined property associated with the electrode during the step of forming the hole;
• stopping the forming a hole step thereby defining a stopping location when the predetermined property reaches a predetermined value;
• verifying that the hole is complete by
• attempting to move the electrode, without a voltage applied thereto, further in the first direction relative to the stopping location.