Anodic metal matrix removal rate in electrolytic in-process dressing II: Protrusion effect and three-dimensional modeling

The electric field distribution around a diamond particle embedded in a met al anode during a steady-state electrolytic in-process dressing (ELID) is c alculated for a few more simple situations: A disk-shaped diamond particle with some protrusion, a spherical diamond particle with a hemispherical pro trusion, and a long diamond particle with a half elliptical protrusion. It is found that the field concentration effect is greatly reduced with protru sion to a value of about 2 when half of the diamond particle is exposed. Th e effect is the largest at the diamond/metal boundary, decreases sharply to a small value at a distance of the order of the size of the diamond partic le. Our analysis suggests that ELID is ideal for exposing diamond in metal- bonded tools. (C) 2000 American Institute of Physics. [S0021-8979(00)02205- 2].