Simulation Assisted Cathode Design for the Manufacturing of Complex Geometries by Electrochemical Machining (ECM)

Abstract

Simulation in electrochemical machining (ECM) offers the capability to distinctly reduce time and costs of the cathode design process and, thereby, increase the economic potential of the manufacturing technology. In recent years, different models for the simulation of ECM have been introduced and successfully validated. However, the application of these models in industry has been hindered by their limitation to two-dimensional geometries. Due to the high demand for computation capacity and robust mesh deformation algorithms a transient multiphysics simulation of the manufacturing process of complex three-dimensional geometries is not economically feasible. A possible approach to a less demanding simulation is the separate consideration of the different physical phenomena as well as the constriction to stationary simulations. In order to evaluate the potential of this approach a complex shaped turbine blade is manufactured by ECM and measured optically. Subsequent, the results are correlated with the results of such a three-dimensional simulation of the electric field and electrolyte flow. Consequently, recommendations for the adaptation of the cathode can be derived.