Direct and inverse problems of shaping by electrochemical generating machining

This paper presents principles and mathematical modelling of new method of shaping, electrochemical generating machining (ECGM). In this method combination of a universal tool-electrode, such as flat electrode, cylindrical electrode, etc., and numerically controlled movement of the tool is used. This variant of electrochemical machining (ECM) has been developed as a result of research performed in order to overcome difficulties related to tool-electrode design and dimensional accuracy in conventional ECM. Software for computer-aided engineering of ECGM has been developed. It allows to simulate machining process and helps in input parameter selection. Also, it allows to solve the inverse problem of ECGM, defined as finding the movement of tool-electrode that is required to obtain given shape of workpiece. Results of computer simulations of machining and tool-electrode motion planning are presented in this paper. The details of experimental set-up, results of actual shaping and verification of iterative method used to solve the inverse problem of ECGM are also discussed. Article Outline