Design and analysis of ECM toolings

Abstract Existing analytical methods for tooling design in electrochemical machining (ecm) are inaccurate so tools have been designed by trial and error which is costly and time consuming. This paper presents a modified ecm theory which gives comparatively accurate results especially for simple shaped workpieces. For complex shaped workpieces and situations, a finite element formulation of the ecm problem has been developed. Results agree well with experimental values. A parametric study of the process which highlights certain guidelines for ecm tooling designers is also presented