Design of Pulsed Electrochemical Machining Processes Based on Data Processing and Multiphysics Simulation

Abstract

The process principle of electrochemical machining (ECM) is based on anodic material dissolution at the interface between the workpiece surface and an electrically conductive solution without any mechanical or significant thermal impact on the workpiece surface. As the material removal mechanism is contact- and force-free it is independent of mechanical properties of the workpiece material such as strength or hardness. In this paper, a methodology to perform the process design of pulsed electrochemical machining (PECM) for manufacturing a three-dimensional geometry based on a sequence of standardized material characterization experiments, data processing and multiphysics simulation is shown. As a part of parameter studies, the machining parameters cathode feed rate and process voltage were varied to determine their influence on the resulting workpiece geometry. Resulting process conditions as for example the working gaps and electric current density distributions were analyzed and compared with experimental results.