Abstract

The paper describes a computer package based on the FEM (Finite Element Method), which simulates the Electrochemical Machining (ECM) process. The FEM is used to determine the two-dimensional potential and flux distributions in the electrolyte, in order to estimate surface erosion for a finite time-step. Algorithms have been developed which automatically change the FE mesh, to simulate moving boundaries for tool movement and workpiece erosion. The complex flux distributions produced in the electrolyte have yielded considerable insight into the erosion process for the tool shapes used in practice.

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