Application of FEM to tool design for electrochemical machining freeform surface

Accurate prediction of tool shape is one of the key points in electrochemical machining (ECM). This paper proposes an approach using finite element method (FEM) to design tool in ECM. This method is capable of designing three-dimensional freeform surface tool from the scanned data of known workpiece. It possesses high computing efficiency, good accuracy and flexible boundary treatment without the need for iterative procedure. An example of tool design for turbine blade is given to demonstrate this method.