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Current Density Distribution and Material Removal Behavior on the Graphite/Iron-matrix Interface in Cast Iron Under Pulse Electrochemical Machining Conditions

O. Weber1 R. Kollmannsperger2 D. Bähre2
1Center for Mechatronics and Automatization, Saarbrücken, Germany
2Institute of Production Engineering, Saarland University, Saarbrücken, Germany

Current density distribution in a cast iron microstructure

The Pulse Electrochemical Machining is especially suitable for the precise production of complex geometric contours with high precision and high surface quality demands in workpieces in series manufacturing. During this process, the negative structure of an electrode is copied to the workpiece without sub-surface damages. An adequate knowledge of the current density distribution and thus of the material removal behavior is required to plan the process according to the material properties and to effectuate surface qualities suitable for industrial applications. Therefore, a simulation model was implemented and developed in COMSOL Multiphysics 4.2a in order to identify the optimal process conditions. The cast iron microstructure was directly imported using the image-to-material function.

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