Study on the dynamic generation of the jet shape in jet electrochemical machining

Jet Electrochemical Machining (Jet-ECM) is a technology for fast creating microstructures into metallic parts without any thermal or mechanical impact and independent from the material's hardness. The processed surface is very smooth and no tool wear occurs. The Jet-ECM process depends strongly on the shape of the jet which is hardly predictable. In a previous study Hackert (2010) built a numerical model with COMSOL Multiphysics based on a predefined jet shape. In the present study a new model was created integrating fluid dynamics using the level set method for two-phase flow. According to the Jet-ECM process the simulation was divided into two steps. In the first step the jet is formed. In the second step the anodic dissolution is simulated by deforming the geometry. The dynamic behavior of the electrolyte jet could be simulated during the dissolution process. So effects became visible which affect the machining results. The results of the present study lead to a better understanding of electrochemical machining via electrolytic free jet. Especially a secondary electric contacting of the nozzle by electrolyte reflected from the work piece could be proven.