Simulation of Anodic Dissolution in Electrochemical Machining and Tool Design using the Sensitivity Method

Electrochemical machining process (ECM) is one of non-traditional machining processes used in various industries due to certain advantages of this process. This machining process is based on the anodic dissolution so having no contact between work piece and tool leads to less tool wear and eliminating cutting forces that are some of the most important benefits of electrochemical machining. There is not still an acceptable method to predict the workpiece shape for a specific tool and also desired tool for a given cavity because of the complexity of this process while using conventional trial and error method to extract the shape of the workpiece and the tool is time consuming and costly. Simulation of Electrochemical machining process is a useful method to overcome this problem and let us to design and predict noted parameters while reducing costs and improving time are achievable. In this paper anodic dissolution in each time step has been simulated using finite element method to simulated electrochemical machining process. Then, using results of the simulated model and the sensitivity algorithm extraction of improved tool shape and desired workpiece are possible. The results demonstrate the ability of the new method proposed in this paper for simulation of electrochemical machining process and design tool.