Application of large deflection analysis for tool design optimization in an electrochemical curved hole machining method

This paper describes the optimization of the tool design and structure in an electrochemical curved hole machining method. Curved holes can be machined using a flexible tool which can be curved by the hole being processed by the tool itself. The curvature of the hole can be determined by the tilt angle of the electrode tip attached to the end of the tool. The tool design was optimized by a numerical analysis of the electrostatic field and a large deflection to reduce the radius of curvature and to improve machining efficiency. Machining tests showed that the curved hole shape is controlled by the detailed electrode shape and the feed rate of the electrode. The calculated curved hole shape agreed with the form of the holes machined experimentally.