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Multiphysics Simulation of the Electrochemical Finishing of Micro Bores


M. Hackert-Osch├Ątzchen1 M. Kowalick1 G. Meichsner2 A. Schubert12
1Chemnitz University of Technology, Chemnitz, Germany
2Fraunhofer Institute for Machine Tools and Forming Technology IWU, Chemnitz, Germany


3D sectional view of the velocity field of the electrolyte.

For several high-precision applications, especially in hydraulic systems and fuel injectors, micro bores are needed. In most cases the shape of the injection hole, especially the edge rounding, has a significant influence on the atomization of fluids and therefore on the combustion process. Usually these micro bores are machined by electrical discharge machining (EDM). Due to the process characteristics of EDM sharp edges arise and a specific influence on the edge shape is not possible. For this reason a specific adjustment of the edge rounding is required. Therefore an Electrochemical Machining (ECM) process has been developed and investigated by help of COMSOL Multiphysics.

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