While micro electrical discharge machining is gaining greater importance in industry and research circles, there remain persistent difficulties with the handling of the microtool. In this study, we propose the "peeling tool" method to overcome tool handling difficulties. This new method is based on separately coating a micro pin or micro wire electrode with a low melting temperature (LMT) alloy before machining in order to form a thick shank for easy holding. The coated pin electrode is then held in a conventional collet chuck. As machining progresses, the LMT alloy coat is easily melted and the micro pin or the micro wire is peeled effectively for microhole drilling. We discuss the production of peeling tools and their application to microhole machining.
