Abstract:  In order to improve the material removal localization of workpiece, uninsulated tools, sideinsulated tools and retracted tip tools are investigated. Electrolyte between anode and cathode is the main research object in the paper. Computational models of electric field are developed, and the distribution of electric potential and current densities in the machining gap are obtained through numerical simulation method. By the numerical results the effects of using retracted tip tools on entrance quality are researched. Furthermore, effects on machining accuracy and efficiency of using retracted tip tools are analyzed, and optimum parameters are obtained based on the simulation results. Results show that good machining accuracy can be obtained with the optimum parameters that retracted tip depth is 50μm, machining voltage 5V and feed rate 3μm/s.

Key words:  electrochemical micromachining, retracted tip tool, numerical simulation of electric field