Clarification of gap phenomena in precise electrochemical machining by implementing a "virtual sensor"

Gap phenomena in precise electrochemical machining (PECM) have been scarcely investigated. State-of-the-art measurement technology does not allow the recording of temperature, gas evolution and electrical conductivity on the time scale of the applied electric pulses. Existing technologies are limited to time-averaged values of the mentioned quantities. However, substantial progress has been made in describing electrochemical processes by multi-physic simulation models. Hence, the developed models can be used to determine state variables within the electrolyte gap by means of a virtual sensor. This paper presents a model for the simulation of electrolyte velocity, temperature, gas evolution and electrical conductivity in the flow channel during one oscillation in PECM. It is characterize d by the abstinence of common short-cut methods and a high degree of coupling between the implemented physical phenomena. Therefore, it precisely describes the development of the mentioned quantities during PECM. It will help to achieve an improved fundamental understanding of the process as well as to optimize machining parameters with respect to economic and qualitative requirements.