Electrochemical machining (ECM) or erosion, is a process for shaping materials by means of the
anodic dissolution of a work-piece using suitably shaped cathodes? However, the predictability
of the process is poor due to current density variations over the electrode contour leading to poor
dimensional tolerances.
This paper describes how the process can be entirely simulated by computer. A model of the
electric field during erosion is constructed based on the Laplace equations for the field. From the
distribution of the electric field, it is possible to continuously calculate the current density at each
point on the work-piece for the whole machining process. In this way, it is possible to predict the
final work-piece contour by running the simulation program instead of the real process.
Simulations for cylindrical, conical and spherical electrodes were carried out and compared to
actual eroded parts.Mechanical Engineerin
