A Novel Modeling Approach for the Simulation of Precise Electrochemical Machining (PECM) with Pulsed Current and Oscillating Cathode

Simulation in electrochemical machining (ECM) offers the capability to distinctly reduce time and costs of the design process and, thereby, increase the economic potential of the manufacturing technology. In recent years, different models for the simulation of ECM with direct current (DC-ECM) have been introduced and successfully applied to varying geometries. Furthermore, first approaches to model the effect of ECM with pulsed current have been presented. However, state of the art machine tools additionally apply an oscillation of the cathode to further improve surface quality and machining precision. To date there exists no validated model for this precise ECM (PECM) process. Therefore, this paper outlines the challenges emerging from considering cathode oscillation in ECM simulation models. Based on an overview of existing models for ECM with pulsed current, conclusions are drawn which concepts can be adopted for the modeling of precise ECM and which phenomena require the introduction of new approaches. Lastly, a model for the simulation of precise ECM is presented. This model accounts for the flow field of the electrolyte, the evolution of temperature in the machining gap as well as the resulting electrical field and finally the material removal.