Generic aspects of tool design for electrochemical machining

This paper concerns some of the generic aspects of tooling design for the electrochemical machining (ECM) process. The work described was carried out at Earby Light Engineers Ltd. (ELE) in Lancashire, UK. This company had little previous experience of the ECM process and the design of ECM tooling. Thus, an aim was to develop a design brief for future production of ECM tooling. The objectives were to study electrolyte flow, the problems occurring during development and to derive generic design solutions arising. In addition, it was required to identify factors, such as insulation requirements and machined face considerations, that could relate to other ECM components. These observations would then be made use of when producing subsequent ECM electrodes. The findings are derived from work carried out in adapting new electrodes for a casting gate removal process.