Multiphysics Simulation of the Material Removal in Jet Electrochemical Machining
Multiphysics Simulation of the Material Removal in Jet Electrochemical Machining
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DOI：
10.1016/j.procir.2015.03.098
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发表时间：
2015
期刊：
影响因子：
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通讯作者：
M. Hackert-Oschätzchen;R. Paul;M. Kowalick;André Martin;G. Meichsner;A. Schubert
中科院分区：
文献类型：
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作者：
M. Hackert-Oschätzchen;R. Paul;M. Kowalick;André Martin;G. Meichsner;A. Schubert
喷射电解加工(Jet-ECM)是一种快速、灵活地在金属零件中生成微结构和微几何图形的技术，它独立于材料的硬度，并且没有任何热或机械冲击[1]。加工过程中刀具无磨损，加工表面非常光滑[2]。喷射-电解加工过程强烈地依赖于电解液射流的形状。在之前的一项研究中，Hackert[3]基于预定义的喷流形状，用COMSOL多物理建立了一个数值模型。随着处理时间的延长，该模型的模拟溶出结果与实验结果逐渐不同。为此，建立了用Level Set方法对两相流进行流体力学集成的多物理模型。此外，在本研究中还考虑了工件与电解液界面处的界面电阻。根据实际的Jet-ECM加工过程，将模拟分为两个步骤。在第一个模拟步骤中形成射流，在第二个模拟步骤中通过变形几何形状来模拟阳极溶解。可以模拟电解液射流在材料去除过程中的动态行为。因此，影响加工结果的效果是显而易见的。
Jet Electrochemical Machining (Jet-ECM) is a technology for quickly and flexibly generating micro structures and micro geometries in metallic parts independently from the material's hardness and without any thermal or mechanical impact [1]. In the process no tool wear occurs and the machined surface is very smooth [2]. The Jet-ECM process strongly depends on the shape of the electrolyte jet. In a previous study Hackert [3] built a numerical model with COMSOL Multiphysics based on a predefined jet shape. The simulated dissolution results of this model progressively differ from experimental results with increasing processing time. Hence, a multiphysics model which integrated fluid dynamics using the level set method for two-phase flow was created. Furthermore, in the present study the electric boundary resistance at the interface of workpiece and electrolyte is considered. According to the real Jet-ECM process the simulation is divided into two steps. In the first simulation step the jet is formed, and in the second simulation step the anodic dissolution is simulated by deforming the geometry. The dynamic behavior of the electrolyte jet could be simulated during the material removal process. So effects became visible which affect the machining results.