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Optimized design of electrochemical machining processes by a combination of 3D simulation and rapid prototyping of cathodes

Optimiertes Auslegen von elektrochemischen Abtragprozessen durch Kombination von 3D Simulation und Rapid Prototyping von Kathoden
 
: Spille-Kohoff, Andreas; Schulze, Robin; Meichsner, Gunnar; Hackert-Oschätzchen, Matthias; Busan, Stefan

Hassel, Achim Walter:
International Symposium on Electrochemical Machining Technology, INSECT 2015. Proceedings : 12.-13. November 2015, Linz
Aachen: Shaker, 2016 (Berichte aus der Materialwissenschaft)
ISBN: 978-3-8440-4728-8
ISBN: 3-8440-4728-X
pp.35-42
International Symposium on Electrochemical Machining Technology (INSECT) <11, 2015, Linz>
English
Conference Paper
Fraunhofer IWU ()
electrochemical machining; optimized design EC processes

Abstract
The design of electrochemical machining (ECM) processes is a time-consuming challenge due to its complex mechanisms [1, 2]. The sampling of new materials or complex geometries is mainly done through empiric experiments. This method is high-grade inefficient since a lot of unusable test workpieces are produced [3].
Within the BMBF funded research project SIREKA, an optimized design of electrochemical machining processes by a combination of 3D simulation and rapid prototyping of cathodes is intended. Simulations of metal dissolution based on experimentally determined dissolving material characteristics are used to examine the ECM process in detail with regard to effects of electrodynamics, fluid dynamics, thermodynamics, transport of dissolved metal and generated gas bubbles. Optimized cathode shapes are exported as STL data files and generated in short time via rapid prototyping like fused deposition modeling or PolyJetTM-technology. The contact ranges on the cathode are generated on the plastic material by metal coatings.
The paper shows first results of the project concerning the 3D simulation of ECM for complex 3D parts, including flow, electric potential, current density and temperature distributions.

: http://publica.fraunhofer.de/documents/N-367460.html