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, said method comprising the steps of:

• (a) providing an electrically-conductive electrode contained within a spindle assembly, in a pre-selected distance and position relative to the titanium-based work-piece;
• while electrically powering the electrode and the work-piece with a power supply;
• (b) circulating fluid electrolyte through at least two pathways in the machining apparatus;
• wherein one pathway comprises an internal conduit within the spindle assembly;
• and 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, to remove material from the work-piece at a relatively high rate, using a high-speed electro-erosion (HSEE) process.