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 of internal precision and micro-geometries with high aspect ratios by process-state-dependent electrolyte management‘ (ElAs) the aim is to develop a new combination of high pressure flush and a flexible electrode concept. Experimental research of model geometries regarding to the electrode shape, the inducted compression, the precision, the surface and the current efficiency are content of the project. Multiphysics simulations are applied to characterise the ElAs technology.