Abstract
Micro-structures on metal surface can be realized with high precision and good surface quality by air-shielding electrochemical micromachining (AS-EMM). However, fundamental understanding of the process and particularly interaction between the electrolyte jet and the surrounding gas flow is limited. In order to obtain the material dissolution process in AS-EMM, a hybrid numerical approach based on a multiphysics approach is presented to simulate the process. Firstly, a two phase flow (gas-fluid) model in the interelectrode gap is generated and the void fraction of gas in the machining gap is obtained based upon finite element analysis software Fluent Inc. Then, a multiphysics model encompassing fields of fluid flow, electric and temperature is developed to analyse the material erosion process on the workpiece surface using COMSOL software. The void fraction of the gas, the current density distribution, the electrolyte temperature in the machining gap which are known to influence material removal and machining evolution process are obtained for typical machining operations. Verification experiments were done based on the comparison results between electrochemical micromachining (EMM) and AS-EMM at different selected time step. An aggregated deviation of less than 11.8% between experimental and theoretical results has been observed.
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