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A method of fabricating convex plate-shaped micro electrode was proposed based on the electrochemical etching principle. The square sectional electrodes were prepared in advanced using wire-EDM, The micro cylindrical electrode was fabricated firstly by using the eletrochechemical etching method. Then the top end was insulated to protect it from etching. Then the convex plate-shaped micro electrode was obtained in subsequent etching. Comparative experiments in drilling micro-hole in stainless steel with the thickness of 1mm were done by using the cylindrical and convex plate-shaped micro electrode. Results shows that the better locality, smaller side-gap and hole taper could be obtain by using convex plate-shaped micro electrode.

In this study the prediction of the erosion profiles during ECM of the spiral hole was presented. By assumptions, the major points were simplified into one-dimensional problems. The theoretical and computational model was built to illustrate the profile movement as the time elapses. The analysis was based on the law of electrolysis and the software MATLAB was used. Verifications were done through experiments and the deviation was 7.5% between theoretical and experimental result. On the basis of the prediction of the erosion profile, the applied parameters could be estimated.