研究开发适合于绿色高效电火花成形加工要求的油包水微乳液，寻找其电加工性能参数与其各组成成分配比间的规律关系；研究油包水微乳液流经工具电极与工件间的微小间隙流阻特性，建立其间隙流阻的数学模型；研究工件加工表面的微观结构形貌特性，揭示其形成的微观机理；研制专用高效节能脉冲电源，建立其控制系统的数学模型；研究工作液、电参数、加工极性和冲液方式等对生产率、加工精度和电极损耗等的影响作用，揭示其影响规律关系。本项目的独特之处在于率先提出研制油包水微乳液替代油类工作液实现绿色高效电火花成形加工的新方法，以及采用混气油包水微乳液高压内冲液的方法提高工作液进出放电加工间隙和排出电蚀产物效果的新思路，可大幅改善电火花成形加工技术的工作环境，提高其加工效率。本项目可以开发出一种绿色高效水基介质电火花成形加工新技术，建立其应用基础理论体系，丰富特种工的理论和内容，提升国产电火花加工机床的技术水平和国际竞争力。

Water-in-oil microemulsion suited for high-efficiency green die sinking EDM process is researched. The relationships between electromachining performance parameters of the microemulsion and different composition ratios of the microemulsion are searched. The flow resistance of water-in-oil microemulsion flowing through the small gap between tool electrode and workpiece is studied. Mathematical model of the flow resistance is established. Microstructure topography on the workpiece surface machined by high-efficiency green die sinking EDM is investigated. The formation mechanism of the microstructure topography is discovered. High-efficiency and energy-saving pulse generator suited for high-efficiency green die sinking EDM process is developed. Mathematical model for control system of the pulse generator is established. Effects of working fluid, electrical parameter, electrode polarity and fluid-jet method on productivity, machining accuracy and electrode wear of the high-efficiency green die sinking EDM process are investigated. Relationships between working fluid, electrical parameter, electrode polarity and fluid-jet method and the process performance are discovered. A new method using water-in-oil microemulsion instead of oil working fluid to achieve high-efficiency green die sinking EDM, and new methods that enhance the effects of working fluid passing in and out of the discharge gap and materials eroded by EDM to be ejected form the discharge gap with mixed-gas water-in-oil microemulsion high pressure jet are firstly proposed. Working environment of die sinking EDM is greatly improved. Machining effciency of die sinking EDM is enhanced. A new kind of high-efficiency green die sinking EDM process can be developed in this project. Basic theory system of the high-efficiency green die sinking EDM process can be established. Non-traditional machining theory, technological level and international competitiveness of EDM machine tool can be improved.