Enhancement of accuracy of dimensional electrochemical processing by a wire electrode on the basis of three-dimensional electrostatic field modeling

Combined technology for the sequential use of electroerosive treatment and electrochemical machining with a wire electrode allows the surface to be structured and the metal components to be fused with high accuracy, regardless of the strength and hardness of materials. Within the scope of this study, some issues which may limit the further development of the proposed technology are eliminated. A simple three-dimensional model by the finite element method is used to calculate the distribution of primary current on the surface of the anode. Three-dimensional results are compared with the data of two-dimensional analytical modeling. This allows to check the accuracy of the algorithm. As a result of the calculations, it is established that a cathode with an insulating layer applied to the side wall can improve the localization and accuracy of the treatment