A novel approach for the efficient modeling of material dissolution in electrochemical machining

INTERNATIONAL JOURNAL OF SOLIDS AND STRUCTURES

卷:229

Article

van der Velden, Tim¹  Rommes, Bob²  Klink, Andreas²  Reese, Stefanie¹  Waimann, Johanna¹ 

[1] Rhein Westfal TH Aachen, Inst Appl Mech, Mies van der Rohe Str 1, D-52074 Aachen, Germany

[2] Rhein Westfal TH Aachen, Lab Machine Tools & Prod Engn WZL, Campus Blvd 30, D-52074 Aachen, Germany

关键词: Anodic dissolution;    Electrochemical machining;    Finite element method;   

DOI  :  10.1016/j.ijsolstr.2021.111106

来源: Elsevier

【 摘 要 】

This work presents a novel approach to efficiently model anodic dissolution in electrochemical machining. Earlier modeling approaches employ a strict space discretization of the anodic surface that is associated with a remeshing procedure at every time step. Besides that, the presented model is formulated by means of effective material parameters. Thereby, it allows to use a constant mesh for the entire simulation and, thus, decreases the computational costs. Based on Faraday's law of electrolysis, an effective dissolution level is introduced, which describes the ratio of a dissolved volume and its corresponding reference volume. This inner variable allows the modeling of the complex dissolution process without the necessity of computationally expensive remeshing by controlling the effective material parameters. Additionally, full coupling of the thermoelectric problem is considered and its linearization and numerical implementation are presented. The model shows good agreement with analytical and experimental validation examples by yielding realistic results. Furthermore, simulations of a pulsed electrochemical machining process yield a process signature component of the surface roughness related to the specific accumulated electric charge. The numerical examples confirm the simulation's computational efficiency and accurate modeling qualities. (C) 2021 Elsevier Ltd. All rights reserved.

【 授权许可】

Free