Abstract: Fabrication of deep and micro holes on the nickel-based superalloy blade of aero engine has been a difficult problem in the field of aviation manufacturing.An electrochemical drilling process for fabricating deep and micro holes with high efficiency is introduced.In order to study the influences of high speed micro spiral electrode on machining accuracy and machining efficiency,the simulation of the gap flow field are carried out.The simulation results show the gas film with good insulation effect around the electrode can eliminate the second electrolysis of the hole wall and improve the machining accuracy greatly.In addition,the fresh electrolyte outside were forced into the machining area due to the negative pressure.Enhanced mass transfer is performed well,which can improve the machining efficiency significantly.Finally,the simulation results above were verified by the experiments,which shows that the micro electrochemical drilling process for fabricating deep and micro holes has a huge potential and broad application prospects.

Key words: micro electrochemical drilling, high speed spiral electrode, simulation, gap flow field, gas film