Numerical Simulation for Thermal Profile of Electro Chemical Machining (ECM) Process

Moarrefzadeh, Ali
September 2011
International Review of Mechanical Engineering;Sep2011, Vol. 5 Issue 6, p1071
Academic Journal
Electrochemical machining (ECM) is a method of removing metal by an electrochemical process. It is normally used for mass production and is used for working extremely hard materials or materials that are difficult to machine using conventional methods. The thermal effect of ECM that specially depends on the electrical arc and chemical process and temperature field of it in workpiece, is the main key of analysis and optimization of this process, from which the main goal of this paper has been defined. The need for complex and accurate three dimensional (3-D) micro components is increasing rapidly for many industrial and consumer products. Electrochemical machining process (ECM) has the potential of generating desired crack-free and stress-free surfaces of micro components. This paper reports a study of pulse electrochemical micromachining (PECMM) using ultra short (nanoseconds) pulses for generating complex 3-D microstructures of high accuracy. A mathematical model of the micro shaping process with taking into consideration unsteady phenomena in electrical double layer has been developed. The software for computer simulation of PECMM has been developed and the effects of machining parameters on anodic localization and final shape of machined surface are presented.


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