A user-friendly simulation software tool for 3D ECM

In this paper, a new and general applicable simulation software for three dimensional ECM calculations is presented. The software is fully integrated within the CAD package SolidWorks® and enables to perform ECM design directly starting from scratch or by reading in existing CAD files (STEP, AutoCad, IGES, etc.). A hybrid structured-unstructured grid generator is incorporated within the software that produces the high quality meshes needed to perform the 3D ECM calculations. The software is very user-friendly with full windows interface and can visualize results using color plots, isolines and streamlines in 3D and on random 2D cross-sections. The model takes into account the internal electrical resistivity of the electrodes and the interaction with the external electrical equipment. In this paper, the numerical model and solution method behind the software are presented and applied in case of the manufacturing of a die and the formation of a cavity.