Transient simulation of electrochemical machining processes for manufacturing of surface structures in high‐strength materials

Transient simulation of electrochemical machining processes for manufacturing of surface structures in high‐strength materials

Electrochemical machining (ECM) is a method for removing metal by anodic dissolution. At the interface between the workpiece surface and an electrically conductive fluid (electrolyte), the material is dissolved locally without direct physical contact to the cathodic tool. Due to the force‐free natur...

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Bibliographic Details
Published in:Engineering reports (Hoboken, N.J.) Vol. 4; no. 7-8
Main Authors: Loebel, Sascha, Zinecker, Mike, Steinert, Philipp, Schubert, Andreas
Format: Journal Article
Language:English
Published: Hoboken John Wiley & Sons, Inc 01-07-2022
Wiley
Subjects:
Alloys
Anodic dissolution
Cathodic dissolution
Current efficiency
Data acquisition
Data processing
Digital twins
Dissolution
Efficiency
Electric contacts
Electrochemical analysis
Electrochemical machining
Electrolytes
Experiments
Geometry
Hard materials
high‐strength materials
Impellers
Manufacturing
multiphysics simulation
Nickel base alloys
precision manufacturing
process design
Process parameters
Product development
Rhenium
Rhenium base alloys
Simulation
Simulation models
Superalloys
Titanium aluminides
Titanium base alloys
Turbomachinery
Velocity
Waspaloy
Workpieces
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Summary:Electrochemical machining (ECM) is a method for removing metal by anodic dissolution. At the interface between the workpiece surface and an electrically conductive fluid (electrolyte), the material is dissolved locally without direct physical contact to the cathodic tool. Due to the force‐free nature of the process, ECM is used for machining high‐strength or hard materials, such as titanium aluminides, Inconel, Waspaloy, and high nickel, cobalt, and rhenium alloys. However, determining suitable process parameters remains challenging due to their interacting effects on working distances during the machining process. Therefore a simulation‐based approach to process design substantially reduces resource and time investment to achieve the desired geometry of the finished part. This methodology requires data about the materials electrochemical properties, such as removal velocity and current efficiency, which have to be obtained experimentally. In this study, a methodology for acquiring and processing this data as well as the development of multiphysics simulation models is presented exemplarily for manufacturing a centrifugal impeller with a diameter of 14 mm consisting of the nickel alloy Inconel 713C for use in turbomachinery. A simulation‐based approach to the design of electrochemical machining processes substantially reduces resource and time investment. In this study, a methodology for acquiring and processing data on material properties as well as the development of multiphysics simulation models is presented for the manufacturing a centrifugal impeller consisting of the nickel alloy Inconel 713C for use in turbomachinery.
Bibliography:Funding information
European Regional Development Fund, 100291455; Freistaat Sachsen, 100291455
ISSN:2577-8196
2577-8196
DOI:10.1002/eng2.12360