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
Published in 2013

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 deformed geometry interface were used. It could be demonstrated, that the maximal removal took place at the edge of the bore hole and only a slight removal at the internal bore wall. This reflects the high localization of the erosion area. Based on this work an industrial setup was realized and the feasibility of targeted adjustment of the flow of micro bores by inverse Jet Electrochemical Machining could be proved.