Electrical discharge drilling (ED-drilling) is a widespread machining method used to bore small holes with a high aspect ratio. This paper presents additional methods by which ED-drilling can improve machining speed, tool wear, and machined surface quality. Firstly, for high machining speed, and low tool wear, a new-type electrode that was ground on one side or both sides of the cylindrical electrodes was suggested to expel debris. The debris which is generated during the machining process can cause sludge deposition and secondary discharge problems: major reasons to decrease machining speed. This new-type electrode also reduced tool wear that was due to the decrease of unstable discharge in a machining gap by helping to expel waste water and debris from the gap. Secondly, to improve the machined surface roughness, an electrolyzation process was included after drilling. This process made the machined surface smooth by means of an electrochemical reaction between an electrode and a workpiece. In this study, the machining speed, electrode wear, and surface roughness were improved by the newtype electrode and the electrolytic process.
