Abstract
Electrochemical micromachining (EMM) is an anodic dissolution process which governs by Faraday’s laws of electrolysis. The accuracy of the machining de-pends on the tool design as the streamline of current density formed in between the tool and the workpiece (electrodes) depends on it. In the present paper, two different tool-tips namely flat and ball end are considered for investigation. The complete set-up is modeled in the COMSOL Multiphysics® software coupling electrochemistry and fluid flow. The current density develops during EMM for both the tool-tips are used for analysis. The tool material is tungsten and work-piece material is stainless steel. Keeping parametric conditions constant for the two, simulation was performed. It was observed that more uniform current developed for ball end compared to flat end. It leads to a decrease in overcut of 120 µm in ball tip than the flat end. The fluid flow shows flushing of debris particles from the interelectrode gap is more effective in ball end than the flat end tooltip.
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