Multi-Physics Simulation of Electro-Chemical Machining Process for Three-Dimensional Compressor Blade

Abstract

Electro-Chemical Machining (ECM) is an advanced machining technology. It has been applied to highly specialized fields such as aerospace, aeronautics and medical industries. However, it still has some problems to be overcome. The efficient tool-design, electrolyte processing, and disposal of metal hydroxide sludge are the typical ones. To solve such problems, CFD is expected to be a powerful tool in the near future. However, the numerical method that can satisfactorily predict the flow has not been established because of the complex flow natures. In the present study, we develop a multi-physics model and a numerical procedure to predict an ECM process. They are verified to the canonical ECM process for a two-dimensional flat plate, and then applied to the ECM process for a three-dimensional compressor blade. It is exhibited that the present model and numerical procedure can satisfactorily predict the final shape of the blade. In addition, using the computed results, the multi-phase flow, thermal and electric fields between the tool and the blade are numerically investigated.

Research Progress on Electrochemical Machining Technology

“…To ensure the design accuracy of the tool cathode, it is essential to consider the coupled multiphysics fields in ECM, such as the electric field, flow field, electrochemical field, and thermal field. M. Zeis et al [7] and T. Fujisawa et al [8] developed multi-physics mathematical models for ECM of complex surfaces, performing numerical simulations based on the workpiece anode's contour to determine the tool cathode's geometric shape. When the workpiece anode is too large or the structure is too complex, it is necessary to design the tool cathode structure in sections to optimize the machining process [9].…”