Abstract
In this paper, a novel electrochemical machining (ECM) method to create holes with complex internal features was presented, in which a tool electrode with non-uniform surface resistance was adopted to shape the inner surface of the hole. The modeling and simulation of creation process of hole with complex internal features was carried out to investigate the electric potential distribution on the electrodes′ surface and in the electrolyte, and the evolution of the shape of inner surface of the hole. Effect of surface conditions of the tool electrode on the shape of the inner surface was also discussed. A prototype of the tool electrode with non-uniform surface resistance was fabricated to verify the feasibility of the proposed method. Simulation results showed that the proposed ECM method has the potential to create holes with complex internal features with relatively simple control system.
