Over the last few years several models have been suggested for analytical design of tools used in electrochemical machining of complex shaped workpieces. However, little success has been achieved in this direction. This is due to complex nature of interaction between the electrochemical machining parameters and lack of clear understanding of the mechanism of metal removal. This paper reports about the application of Finite Element Technique (FET) to design analysis of ECM tools. The results obtained have been compared with the experimental data and a good correlation has been observed. The paper also discusses in detail the computational aspects.

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