Simulation of electrolyte behaviour of industrial electrochemical machining

Electrochemical machining (ECM) has the potential to provide cost-effective solutions for producing precision components in hard, heat- and corrosion-resistant alloys. Any new application of ECM, however, requires a considerable trial-and-error phase to develop the process and required tooling. Simulation models can avoid this iterative process and speed up its adaptation for industrial production. This paper investigates the electrolyte flow in the narrow inter-electrode gaps (100- 400 μm) of ECM since the electrolyte behaviour plays a predominant role in the process stability and the resulting dimensional accuracy and surface finish. The simulation of the electrolyte’s flow rate and pressure correlate with areas of flow starvation or gas bubble generation, leading to sparks and causing process deterioration, as observed in the experimental trials. This model is the first step towards creating a process digital twin for ECM, with the ultimate goal of ensuring process repeatability for industrial mass production of Tribaloy components.