Time averaged temperature calculations in pulse electrochemical machining, spectral approach

Abstract

Simulation of the temperature distribution during the Pulse Electrochemical Machining (PECM) process provides information on system design and guidelines for practical use. The pulses that are applied to the PECM system have to be described on a time scale that can be orders of magnitude smaller than the time scale on which the thermal effects evolve. If the full detail of the applied pulses has to be taken into account, the time accurate calculation of the temperature distribution in PECM can become a computationally very expensive procedure. A different approach is used by time averaging the heat sources of the system. Performing this, the time steps used during the calculations are no longer dictated by the pulse characteristics. Using this approach, computationally very cheap, yet satisfying results can be obtained. In previous work of the authors, the hybrid calculation and the Quasi Steady State ShortCut (QSSSC) were introduced. This method allows to perform simplified calculations while getting satisfactory results. The method introduces errors however, which were quantified using analytical solutions and found to be acceptable. The results applied only to rectangular pulses. In this work, the more general case of arbitrary pulse forms is considered using a spectral approach.

Time-averaged concentration calculations in pulse electrochemical machining, spectral approach

“…For the temperature evolution in the system also, an optimal w* exists to minimize the decaying component on the temperature evolution [10]. The pulse delay for the concentration and the temperature has to be taken the same, since they result from the same current pulses.…”

Low Temperature Interface Modification: Electrochemical Dissolution Mechanism of Typical Iron and Nickel Base Alloys

“…By constructing a multiphysics model and quasi steady state shortcut (QSSSC) method, the temperature field distribution in pulse ECM (PECM) processing has been successfully modeled [18]. To overcome the shortcomings of the QSSSC method, such that it can be used to calculate only rectangular waves, a spectral approach was introduced to successfully calculate the temperature field distribution of PECM under arbitrary waveforms [19]. The thermal imaging simulation for Joule heating was found to be in good agreement with thermal imaging camera results, with the temperature along the horizontal direction of the streamline exhibiting a larger gradient than in the vertical direction [20].…”

Time averaged calculations in pulse electrochemical machining, using a strongly non-linear model

“…Analytical formulae for optimal values of w were presented in the work. The hybrid method and the derived QSSSC have also been used in other work of the authors [18][19][20][21].…”