Experimental and Numerical Modeling of ECMM on Al 7075 T6 Alloy

Abstract

Electrochemical micromachining (ECMM) is a nontraditional machining technique in the area of mechanical engineering. It is more essential to meet the increasing demand of the industries from aero to medical. ECMM is the promising technique, since it has been growing popularity in various areas of applications. In the present study, the optimal combination and influence of process parameters on ECMM while machining Al 7075 T6 alloy are presented using Taguchi analysis and ANOVA. A bare electrode (cathode) has been used for this purpose. Later on, using an optimum combination of process parameters, the hole is drilled with insulated electrode. The ECMM process model has been developed and simulated with a bare tool and insulated tool using COMSOL Multiphysics V5.3a software. The effect of tip reaction on anode profile and stray current machined zone is identified with the electric field, temperature field, and fluid field. The results are validated with experimental results. The simulated predicted model is in close conformity with an experimental model.