Advanced CAD integrated approach for 3D electrochemical machining simulations
Advanced CAD integrated approach for 3D electrochemical machining simulations
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DOI：
10.1016/j.jmatprotec.2007.09.082
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发表时间：
2008-07
影响因子：
6.3
通讯作者：
M. Purcar;A. Dorochenko;L. Bortels;J. Deconinck;B. Van den Bossche
中科院分区：
文献类型：
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作者：
M. Purcar;A. Dorochenko;L. Bortels;J. Deconinck;B. Van den Bossche
电化学加工 (ECM) 工艺中遇到的许多阴极工具/工件配置只能通过真实的 3D 建模进行分析，而不是通过 2D 或轴对称横截面进行分析。本文提出了一种先进的 CAD 集成方法，用于具有强非线性边界条件（包括反应效率和移动阴极工具）的 3D 模拟。该仿真工具完全集成在计算机辅助设计 (CAD) 软件包 SolidWorks® 中，可以从头开始执行 ECM 配置，或者通过读取现有 CAD 文件（STEP、AutoCad、IGES 等）来执行 ECM 配置。该软件工具可以可视化过程不同阶段的电极形状变化轮廓，并使用彩色图、等值线和流线图呈现电流密度和电势分布。电化学过程模型假设电解质被充分搅拌和更新，使得本体和电极处的电流密度由拉普拉斯方程控制。在电极和电解质之间的界面处，非线性边界条件适用于对电极反应进行建模。使用四面体对整个几何结构进行离散化，并应用有限元方法（FEM）来计算势场分布。根据法拉第定律，考虑溶解反应的效率，通过按局部电流密度的比例和方向移动工件表面上的节点来确定电极形状。在每个时间步骤，可以重建完整的 CAD 模型作为下一个计算步骤的直接输入，尤其是当离散模型预计拓扑发生变化时。一个例子涉及不锈钢板的槽 ECM 直至穿孔。将三维结果与二维横截面模拟的可用数据进行比较。这样可以检查 3D ECM 算法的准确性。
Many cathode tool/work piece configurations as encountered in electrochemical machining (ECM) processes can only be analysed by real 3D modelling, rather than 2D or axi-symmetrical cross-sections. This paper presents an advanced CAD integrated approach for 3D simulations with strong non-linear boundary conditions including reaction efficiency and moving cathode tools. The simulation tool is completely integrated in the computer-aided design (CAD) package SolidWorks®, which enables to perform the ECM configuration from scratch, or by reading in existing CAD files (STEP, AutoCad, IGES, etc.). The software tool can visualize the electrode shape change profile at different stages of the process and presents current densities and potential distributions using colour plots, isolines and streamlines. The electrochemical process model assumes that the electrolyte is well stirred and refreshed such that the current density in the bulk and at the electrodes is governed by the Laplace equation. At the interfaces between electrodes and electrolyte, non-linear boundary conditions apply for modelling the electrode reactions. The whole geometry is discretized using tetrahedrons and the finite element method (FEM) is applied to compute the potential field distribution. The electrode shape is found by displacing the nodes on the work piece surface proportional with, and in the direction of the local current density according to Faraday's law, taking into account the efficiency of the dissolution reaction. At each time step the complete CAD model can be reconstructed as a direct input for the next computational step especially when the discretized model expects topology changes. An example deals with slot ECM of a stainless steel plate up to perforation. Three-dimensional results are compared with available data from 2D cross-section simulations. This allows to check the accuracy of the 3D ECM algorithm.