Cathode Shape Design for Steady-State Electrochemical Machining

The inverse or cathode shape design problem of electrochemical machining (ECM) deals with the computation tool required for producing a workpiece anode desired shape. This work applied complex variable method and continuous adjoint-based optimization to solve steady-state shapes different smoothnesses. An exact solution is proven exist only in cases when function describing analytic. solution’s physical realizability shown depend on aspect ratio features surface width standard equilibrium front gap. In where an physically realizable exists, produce accurate numerical solutions; otherwise, produces singularities. For latter cases, demonstrates how perimeter regularization can be compute smooth approximate suitable workpieces within range manufacturing tolerance.