Abstract
When polishing workpiece with sudden dimension or shape change with ECM process, the surface roughness at corner area is found much poorer than that of other areas. This paper is aimed at getting a reasonable interpretation of this phenomenon and obtaining possible solutions to the problem. The effect of possible influence factors, such as shape of the workpiece and tool electrode, the electrolyte flow pattern, inter electrode gap (IEG), machining by-products, etc., were considered. Simulations of current density distribution, electrolyte flow field distribution, bubble distribution were carried out. It was found that the current density distribution on the electrode surface is not only depend on the gap size between electrodes, but also affected by the geometry of the tool electrode and workpiece.
