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2D axisymmetric simulation of the electrochemical finishing of micro bores by inverse jet electrochemical machining

Presentation held at COMSOL 2013, October 23 - 25, 2013, Rotterdam
: Hackert-Oschätzchen, Matthias; Kowalick, Michael; Meichsner, Gunnar; Schubert, Andreas; Hommel, Bernd; Jähn, Frank; Scharrnbeck, Matthias; Garn, Rüdiger; Lenk, Andreas

Preprint urn:nbn:de:0011-n-2668254 (850 KByte PDF)
MD5 Fingerprint: a9c2e3e6781340fc6e497793380a1b49
Erstellt am: 27.11.2013

2013, 7 S.
COMSOL Conference <2013, Rotterdam>
Vortrag, Elektronische Publikation
Fraunhofer IWU ()

Within this publication a wide scope of technology users, system developers and research institutes have worked together in a cooperation project funded by the European Union through the European Regional Development Fund (ERDF) and from state funds of the Free State of Saxony. Focus of the project was the creation of conditions for a quality-oriented mass production of micro bores with defined hydraulic flow. These micro bores are used for several high-precision applications, especially in hydraulic systems. In this case the shape of the micro hole, particularly the edge rounding, has a significant influence e. g. on atomization of fluids [1]. After wide-ranging experimental studies for the desired function, the application of shaped electrodes could be detected to be unsuitable and therefore an inversion of the Jet Electrochemical Machining process has been developed [2]. In this case the erosion area is localized by a continuous electrolytic free jet. Forming a free jet leads to a high localization of the current density resulting in a highly localized machining area [3]. Use of COMSOL Multiphysics® In this study, the inverse Jet-ECM process of micro bore is investigated by help of multiphysics simulations. Figure 1 gives an overview about the process. The nozzle is connected to a positive electrical potential. Zero potential is connected to the tool which is the cathode. For simulating inverse Jet-ECM a fully coupled model has been developed. Therefore the electric currents and the deformed geometry interface were used. Figure 2 shows as example a 2D sectional view of the eroded geometry after 0.1s of machining. It can be seen, that the maximal removal took place at the edge of the bore hole and only a slight removal at the internal bore wall. This reflects the high localization of the erosion area.