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Multiphysics modeling and simulation drives innovation across industries and academia — as is evidenced by the many uses showcased in the technical papers and posters presented by engineers, researchers, and scientists at the COMSOL Conference each year.

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Analysis of an Electrochemical Machining Process for Particle Reinforced Aluminum-Matrix Composites

M. Hackert-Oschätzchen [1], N. Lehnert [1], C. Scherf [2], A. Martin [1], M. Penzel [1], A. Schubert [3],
[1] Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany
[2] Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany
[3] Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany; Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany

At the Technische Universität Chemnitz several academic institutions work on aluminum matrix composites (AMCs) within the Collaborative Research Centre SFB 692 HALS. Besides the development and analysis of these materials one main task is finishing machining of AMCs by an electrochemical ... Read More

Transient Simulation of an Electrochemical Machining Process for Stamping and Extrusion Dies

M. Penzel [1], M. Hackert-Oschätzchen [2], M. Kreißig [1], M. Kowalick [1], M. Zinecker [1], A. Schubert [1], G. Meichsner [3],
[1] Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany
[2] Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany; Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany
[3] Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany

Precise electrochemical machining (PEM) is a non-conventional machining technology, based on anodic dissolution of metallic work-pieces. In this study an additional extension of the precise electrochemical machining with a precise angle-controlled cylinder positioning is aimed. Due to ... Read More

2D Axisymmetric Simulation of Pulsed Electrochemical Machining (PECM) of Internal Precision Geometries

M. Hackert-Oschätzchen [1], M. Kowalick [1], R. Paul [1], M. Zinecker [1], D. Kuhn [1], G. Meichsner [2], A. Schubert [3],
[1] Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany
[2] Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany
[3] Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany; Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany

This study presents investigations on a developed process design for manufacturing internal precision geometries by pulsed electrochemical machining (PECM) with help of multiphysics simulations. Therefore, a 2D axisymmetric transient model was created. The considered physical phenomena ... Read More

Transient Simulation of the Electrolyte Flow in a Closed Device for Precise Electrochemical Machining

M. Hackert-Oschätzchen[1], M. Penzel[1], M. Kowalick[1], G. Meichsner[2], A. Schubert[1,2]
[1]Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany
[2]Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany

Precise electrochemical machining (PEM) is an innovative machining technology which results from further development of the electrochemical sinking. PEM works with pulsed low frequency direct current and oscillation of the tool electrode. As part of the project ‘Electrochemical machining ... Read More

Analysis of the Electrochemical Removal of Aluminum Matrix Composites Using Multiphysics Simulation

M. Hackert-Oschätzchen[1], N.Lehnert[1], M. Kowalick[1], G. Meichsner[2], A. Schubert[1,2]
[1]Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany
[2]Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany

In the Collaborative Research Centre 692 at TU Chemnitz several academic institutions work on aluminum matrix composites (AMCs). These materials consist of an aluminum matrix, which is reinforced by SiC or Al2O3 particles with dimensions less or equal 1 µm. One main task is finishing ... Read More

2D Axisymmetric Simulation of the Electrochemical Finishing of Micro Bores by Inverse Jet Electrochemical Machining

M. Hackert-Oschätzchen[1], M. Kowalick[1], G. Meichsner[2], A. Schubert[1], B. Hommel[3], F. Jähn[3], M. Scharrnbeck[4], R. Garn[5], A. Lenk[5]
[1]Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany
[2]Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany
[3]SITEC Industrietechnologie GmbH, Chemnitz, Germany
[4]SITEC Automation GmbH, Chemnitz, Germany
[5]Continental Automotive GmbH, Limbach-Oberfrohna, Germany

In this study the inverse Jet-ECM process of micro bores is investigated by help of multiphysics simulations. Based on the micro bore of a commercial sample nozzle a model geometry was derived. For simulating inverse Jet-ECM a transient model has been developed. Electric currents and ... Read More

Simulation of a Heated Tool System for Jet Electrochemical Machining

M. Hackert[1], G. Meichsner[2], and A. Schubert[1][2]

[1]Chair Micromanufacturing Technology, Faculty of Mechanical Engineering, Chemnitz University of Technology, Chemnitz, Germany
[2]Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany

Jet Electrochemical Machining (Jet-ECM) is an unconventional procedure using localized anodic dissolution for micromachining. An increasing of the electrolyte temperature will lead to an increase of the electrical conductivity of the electrolyte by about 30% and to a reduction of the ... Read More

Simulating the Influence of the Nozzle Diameter on the Shape of Micro Geometries Generated with Jet Electrochemical Machining

A. Schubert[1][2], M. Hackert[1], and G. Meichsner[2]

[1]Chair Micromanufacturing Technology, Faculty of Mechanical Engineering, Chemnitz University of Technology, Chemnitz, Germany
[2]Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany

Jet Electrochemical Machining (Jet-ECM) is an unconventional procedure for micromachining. Based on localized anodic dissolution three-dimensional geometries and microstructured surfaces can be manufactured using Jet-ECM. COMSOL Multiphysics is used at Chemnitz UT to simulate the ... Read More

Simulation of Heat Transfer on Periodic Microstructured Surfaces for Evaporation Cooling

M. Hackert-Oschätzchen[1], R. Paul[1], M. Penzel[1], M. Zinecker[1], A. Schubert[1]
[1]Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany

Evaporative cooling is a promising cooling method for dissipating high heat fluxes in high power density applications. One possibility to enhance heat flux is a generation of microstructures into the cooler surface. This enlarges the cooler surface and systematically affects the fluid ... Read More

Design of Electrochemical Machining Processes by Multiphysics Simulation

M. Hackert-Oschätzchen, S. F. Jahn, and A. Schubert
Chemnitz University of Technology
Chemnitz, Germany

The principle of electrochemical machining (ECM) is the anodic dissolution of a metallic workpiece at the interface to a liquid ionic conductor under the influence of electric charge transport. This erosion principle works independently from the mechanical hardness of the workpiece and ... Read More

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