Development of a comprehensive computer aided design (CAD) software package for electrochemical machining (ECM) is proposed. The software will be capable of simulating the overall ECM process, provide predictive cathode tool design and recommend optimal operating conditions. The machining parameters and tool shape will be computed by an analytical model accompanied and enhanced by machine-based instructions. The shape changes (and the current distribution) are derived from Laplace's equation for the potential. This equation is solved in an arbitrarily shaped cell subject to the appropriate electrochemical and fluid mechanical boundary conditions, by a highly efficient finite difference techniques which we have implanted earlier. The numerical computations, machine based instructions and a user-customizable data base will be linked together as an expert system for ECM. To assure competent use and acceptability by non-experts, the software will be robust and user-friendly. The user interface will include menus, on-screen instructions, reasonable default values, and extensive graphics for convenient geometry input and easy interpretation of the results.
