Simulation of Micro ECM for Complex-shaped Holes

A novel electrochemical machining (ECM) method using tool electrodes with controlled conductive area ratio to shape the complex inner surface of holes was discussed. The machining process was modeled to investigate the electric potential and current density distribution on the electrodes’ surface and in the electrolyte, and the evolution of shape of inner surface of the hole. The effect of current efficiency was taken into account when determining the machining velocity of target hole. The relationship between conductive area ratio and the machining depth was also discussed. Simulation results showed that this method is capable of creating reverse-tapered micro holes and holes with various complex internal features with relatively simple control system.