The multi-physics analysis for a novel tool structure to improve the accuracy in electrochemical micro-machining

In this study, a novel tool structure (i.e., the conductive cathode tip is retracted into the side-insulated layer) is proposed to improve the machining accuracy in electro-chemical micro-machining (EMM). To deeply understand the effect of this novel tool, a multi-physics model taking electrical field, fluid field, and temperature field into account is developed for simulation. Using this coupled model, the effect of the tip retraction depth and machining conditions on the machined anodic profile is numerically studied to optimize the tool structure and process parameters. Subsequently, comparative experiments between the traditional and novel tool are performed to verify the simulation. The simulated and experimental results both show that the novel tool structure has the potential to effectively improve the shape accuracy and surface quality in EMM.