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 machining of AMCs by electrochemical machining (ECM). The goals are depending on the application whether to resolve the matrix specifically to uncover particles, to resolve the whole composite or to anodize locally the aluminum. For the process design, the electrochemical characteristics of the AMCs have to be analyzed. For that reason an analyzing device is developed using simulation with COMSOL Multiphysics®. Within the simulation especially electrolyte flow and current density (figure 1) are analyzed.