Proposal of Machining Method for Reverse-tapered Hole and its Verification with Simulation

摘要

Reverse-tapered hole is hard to machine with conventional method in some cases. In this paper, the modeling and simulation of reverse-tapered hole creation process using electrochemical machining (ECM) was discussed. A tool electrode with non-uniform surface resistance was designed and the effect of the surface condition of the electrode on the shape of the taper was investigated. COMSOL Multiphysics was used to simulate the electric potential distribution on the electrodes' surface and in the electrolyte, and the evolution of the shape of the reverse-tapered hole. The simulation results showed that the proposed ECM method is capable of creating reverse-tapered hole with relatively simple control system.