Abstract
In this paper, the modeling and simulation of micro-pin forming process using electrochemical machining (ECM) was discussed. The boundary conditions were chosen based on the parameters of ECM experiments. COMSOL Multiphysics was used to simulate the electric potential distribution on the pin surface and in the electrolyte, and the evolution of the micro-pin shape. The anode resistance was also taken into account to simulate the micro-pin forming process. The simulation results showed the same trend with experimental results in terms of the final pin shape and the diameter changing process.
