Abstract
A simple model for tool (cathode) design for plane parallel electrochemical machining and electrochemical drilling has been proposed. Assuming the initial tool shape to be complementary to required work shape, the desirable and predicted anode profiles have been compared and the error between them has been evaluated. Using this error, the correction factor has been calculated to modify the tool shape. This procedure is repeated till the designed tool can produce an anode profile within the prescribed tolerance limits. Using this technique, tools for tapered, flat, exponential, parabolic, and nonstandard work shapes have been designed. Bare tools have been designed for straight and tapered sided holes. Comparison between analytical and experimental results shows a good agreement between them.
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