Measurement and analysis of the geometric characteristics of microholes and tool wear for varying tool-workpiece gaps in electrochemical discharge drilling

•The effect of the T-W gap on the microholes formation by the ECDD is reported.•A T-W gap of 10–30 µm for NaOH and 5–20 µm for KOH electrolyte must be maintained.•The required T-W gap depends on the electrolyte type and its concentration.•Microholes size initially increases and then reduces with fur...

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