Modeling of Wire Electrochemical Machining

The electrochemical machining with a wire tool electrode was studied theoretically. The Laplace equation for the electric field potential and the equation of workpiece surface evolution were used as the mathematical model of the process. A scheme of computer simulation of machining was developed. The scheme involved the numerical solution of the boundary integral equation, which is a consequence of the Laplace equation, by using the method of boundary elements; the determination of a new position of workpiece surface with regard for possible topological changes; and the motion of wire tool electrode along a prescribed path. The machining of typical features (straight slits, slits with corners, openings with square and triangular cross-sections) is analyzed. It is shown that this scheme of simulation can be used for various machining regimes, including the cases of the topological changes of the workpiece surface. The results of simulation agree well with the literature data on the wire electrochemical machining. As a result of simulation, the dependences of the front and side interelectrode gaps on the machining parameters were obtained for various schemes of machining. They can be used for determining the path of wire tool electrode in order to obtain the prescribed shape and sizes of workpiece surface.