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<title-group><doi>137</doi>
<article-title>Analysis of a PECM Electrode Concept for Micro Injection Moulds by Multiphysics Simulation</article-title>
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<author>Henning Zeidler<sup>1</sup>, Andr&#233; Martin<sup>1</sup>, Michael Kowalick<sup>1</sup>, Matthias Hackert-Osch&#228;tzchen<sup>1</sup> and Andreas Schubert<sup>1,2</sup>  </author>

<aff><sup>1</sup>Technische Universit&#228;t Chemnitz, Faculty of Mechanical Engineering, Institute for Machine Tools and Production Processes, Professorship Micromanufacturing Technology, 09107 Chemnitz, Germany  </aff>
<aff><sup>2</sup>Fraunhofer Institute for Machine Tools and Forming Technology IWU, Reichenhainer Str. 88, 09126 Chemnitz, Germany </aff>

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<title>ABSTRACT</title>
<p>In micro injection moulding highly precise cavities are needed to fulfil the requirements in precision and at the same time offer the possibility for easy demoulding. Pulsed Electrochemical Machining (PECM) represents a potential technology for manufacturing mould cavities, because the machined geometries can be equipped with a certain draft angle. In this study the influence of three different electrode concepts on the shape of the draft angle is analysed. The first electrode concept is a non-insulated electrode. As the removal process depends on the distribution of the electric current density, lateral widening increases during the sinking process if a non-insulated electrode is applied. This effect can be reduced by a local insulation of the electrode on its side flanks or by reducing the electrode's cross-sectional diameter by help of an undercut. In order to investigate the influence of these electrode concepts on the resulting geometry, multiphysics simulations of the PECM process were performed. For that purpose a model was created. The machining process was simulated for a processing time of 2400 s. The resulting electric current densities, the removal geometries and the formed radii were analysed and compared to each other.  </p><p><italic>Keywords: </italic>Pulsed electrochemical machining, PECM, Electrode insulation, Electrode undercut, Multiphysics simulation, Electrodynamics, Deformed geometry. </p>
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