Electro-Chemical Machining (ECM) is an advanced machining technology. It has been applied to highly specialized fields such as aerospace, aeronautics and medical industries. However, it still has some problems to be overcome. The efficient tool-design, electrolyte processing, and disposal of metal hydroxide sludge are the typical issues. To solve such problems, CFD is considered to be a powerful tool in the near future. However, the numerical method that can satisfactorily predict the flow has not been established because of the complex flow natures. In the present study, we develop a numerical code and simulate the three-dimensional flow in the ECM process of compressor blades. Visualizing the computed flow field, the characteristics of the flow between the tool and the blade are investigated. It is exhibited that the over-machining occurs due to the Joule’s heating and the flow deviation around the leading and trailing edges.

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