In electrochemical machining the evolution of gas and heat in the electrolyte results in local variation of the gap between the electrodes. The ability to predict these variations for any given operating condition is a prerequisite of proper design of the cathode tool. This paper provides analytical predictions of the change in gap geometry for the one-dimensional steady-state case. Employing the basic conservation laws, a system of coupled nonlinear differential equations is derived for the gas-electrolyte mixture which flows between the electrodes. The assumption of homogeneity of the two-phase mixture is employed throughout the analysis. Numerical results from the solution of the equations are presented graphically and compared with experimental data. The local variation in gap and the relation between current, gap, and applied voltage compare favorably with the experimental data within the ranges of parameters investigated: current density 45–400 amps per sq in., electrolyte flow rate 0.22–0.98 gpm, entrance gap size 0.015–0.020 in., potassium chloride electrolyte normality 0.67–1.14.

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