Simulation-based Study on the Influence of Electrode Shape on Current Flow and Intensity in a Workpiece

This study investigates how the shape of an electrode affects current flow and density in electrochemical machining (ECM). Two distinct electrode designs were evaluated: a standard cylindrical electrode (A) and a chamfered electrode (B). The designs were tested under varying gap conditions between the electrode and a SUS304 workpiece. The experiments utilized a constant 5A current and NaCl as the electrolyte. Current density was measured at gap distances of 1, 3, and 5 mm to assess its influence on machining precision and hole formation. The results revealed that smaller gaps resulted in higher current concentration, which enhanced accuracy but also increased the risk of uneven wear. Electrode B exhibited a more uniform current density compared to Electrode A. These findings can be used as a guide in the optimization of ECM processes for improved performance.