Finite element prediction of tool shapes in electro-chemical machining
by Sandeep S. Patil, Vinod Yadava
International Journal of Design Engineering (IJDE), Vol. 1, No. 1, 2007

Abstract: Electro-Chemical Machining (ECM) is one of the most widely used unconventional machining process for machining electrically conducting materials and for machining complex shapes in difficult-to-cut materials without distortion, scratches, burrs and residual stresses. Due to complex nature of ECM process, it is very difficult to predict accurately the shape of the workpiece for the given tool or designing tools to produce required profile in the workpiece. Different techniques have been applied to predict the shape of tool for given shape in the workpiece. In this work, two-dimensional electric potential model is developed for the determination of electric potential distribution in the ECM interelectrode gap. Initially approximate profile 'guess curve' of tool profile is calculated using cosθ method then cumulative current at each node of the tool profile is calculated. Iteration of the guess curve is moved towards exact shape of tool and simultaneously cumulative current on the tool is checked. Iteration is stopped when cumulative current becomes different at each node on the tool profile to get the final shape of the tool.

Online publication date: Wed, 10-Oct-2007

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