Abstract
Electrochemical machining (ECM) has been increasingly recognized as a potential tool for mini-scale machining. Using the ECM process to erode a hole of hundreds of micrometres on a thin metal sheet is analysed in this paper. The purpose of this study is to predict the hole formation, particularly when boring through the hole. A theoretical method is presented to illustrate how the machined profile evolves. The analysis is based on the fundamental law of electrolysis and the integral of the electrochemical reaction over the finite width of the tool electrode. A concept of redistribution of electric charge is adopted in the model when the hole is bored through. The approach of the model is verified experimentally. © Springer-Verlag London Limited 2004.