Time-dependent Simulation Of Electrochemical
Machining Under Non-ideal Conditions
Author(s)
D. Curry, A. Sherlock, A. Mount & R. Muir
Abstract
Electrochemical machining (ECM) is a manufacturing process based on the
principles of electrolysis. It machines irrespective of workpiece hardness and, as
a result, it is used in the manufacture of parts requiring the use of hard alloys
such as airfoil blades. Die-sinking ECM involves a shaped tool being moved
closer towards the workpiece. Material removal takes place under the influence
of an electric field. Once material removal rates are equal to the tool feed rate the
process is said to have reached equilibrium. At equilibrium the workpiece is an
approximate inverse of the tool shape. Under ideal ECM conditions, a number of
process parameters are assumed to be constant. Industrially however, conditions
are rarely ideal, and it may not be desirable to machine until equilibrium. This
paper presents a time-dependent simulation that includes a model of one of the
changing parameters, the overpotential, which is the voltage required to drive the
electrochemical reactions at the workpiece and the tool. Previous work has
shown that this condition varies throughout the course of machining. Validation
is performed against experimental results, and comparisons are made against
simulation under ideal conditions.
Keywords: electrochemical machining (ECM), simulation, time-dependent,
finite-element analysis, overpotential, non-ideal, non-equilibrium.
1 List of Symbols
V0 Overpotential
n Valency
Vt Applied voltage
A Area of workpiece
electrode
κ Conductivity
I Current
z Gap
dh Material removed
Keywords
electrochemical machining (ECM), simulation, time-dependent,
finite-element analysis, overpotential, non-ideal, non-equilibrium.
Related Book
Other papers in this volume
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