Calculation Of Temperature Fields With
DC And Pulsed ECM
Author(s)
N. Smets, G. Nelissen, J. Deconinck & S. Van Damme
Abstract
During the process of Electrochemical Machining (ECM) metals are
electrochemically dissolved at very high current densities up to 1 A/mm2.
Simulation of the temperature distribution during the process provides interesting
insights and guidelines for practical use. To be able to calculate the temperature
distribution a coupled model with a time accurate solver (second order accuracy)
is implemented. In practice, a pulsed current is applied for reasons of accuracy
and surface quality. Hence the calculation of the temperature field during pulsed
ECM as a function of time is performed, but this can be a very expensive
procedure. The pulses have to be described on a timescale that can be orders of
magnitude smaller than the timescale on which the thermal effects evolve. If one
wants to calculate the temperature evolution one must calculate the effect of all
of these pulses. A new approach is introduced. By replacing the pulsed current
with a constant current, which has the same thermal effect, it is shown that one
can calculate the temperature field in a much more efficient way. The calculation
is done with large timesteps, which is a great improvement. Results of expensive
simulations with pulsed current and cheap simulations with thermally equivalent
constant current are performed and shown to be very comparable.
Keywords: pulsed ECM, PECM, temperature, heat, electrochemical simulation.
1 Introduction
Electrochemical machining (ECM) is an important manufacturing technology in
machining difficult-to-cut materials and shaping complicated contours and
profiles. ECM is the controlled electrochemical dissolution of a metal. In an
ECM cell one can distinguish two electrode types: the workpiece (anode), and
the tool (cathode). Between the electrodes there is a small gap through which an
Keywords
pulsed ECM, PECM, temperature, heat, electrochemical simulation.
Related Book
Other papers in this volume
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