Techniques for modelling electrochemical machining are briefly reviewed before concentrating on the boundary element method for computing the shape of tool profiles. The model described caters for problems which can be represented geometrically in two dimensions; it is iterative in nature and uses the approximate cos θ method to initiate the procedure. Subsequent iterations employ one of three formulations developed for correcting the tool profile to obtain workpiece equilibrium. Linear and quadratic isoparametric elements have been used and their relative accuracy is assessed. Special emphasis is placed on the design of tools expected to need sharp profile discontinuities and the merits of specifying different boundary conditions on the known work surface are examined.
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