Cathode shape prediction in electrochemical machining using a simulated cut-and-try procedure

Abstract

The paper presents a computer simulation of the cut-and-try procedure for designing tool shapes in the electrochemical machining of prescribed work geometry. The procedure is capable of tackling complex work geometries where other existing methods fail. The variation of electrolyte conductivity has also been taken into account. It has been shown that an optimum value of the feed-back factor for iterative modification of the tool shape exists, which results in the minimum number of iterations to achieve the final result. The optimum value of the parameter has been shown to depend on some particular geometrical features. A parameter has been identified which determined the unique tool shape for a prescribed complex work geometry.