CFD Analysis of Flow Pattern in Electrochemical Machining for L-Shaped Tool

Abstract

Electrochemical machining is a non-conventional machining process worked with a principle of Faraday’s law. Due to improper tool design of complicated shapes, there are chances of passivation and boiling of electrolyte in ECM process that causes poor machining. Predicting
the flow pattern is also important to prevent boiling tendency of electrolyte is due to overheating of electrolyte. This project work is for optimizing the design of L-shaped tool and to study the flow pattern, current density distribution, velocity profile, temperature
pattern, turbulence and final shape change of workpiece top surface. Four models with different shaped grooves for supplying electrolyte are evaluated. ANSYS-CFX software was used for simulating this CFD problem. Geometrical model
consists of a circular workpiece made with Iron, 20% brine solution as electrolyte and Lshaped copper tool with different kind of grooves. This problem is considered as a steadystate problem with turbulence model. A potential difference of 10V is applied in between the IEG. The models were simulated for various inlet velocities and the major findings are stated below. The maximum temperature in IEG for all models has a decreasing tendency with respect to
the increase in inlet velocities. The maximum current density has increasing tendency with respect to increase in inlet velocities. MRR and turbulence also increase in inlet velocities. Tendency of passivation is decreasing in case of all models with increasing velocity. Model 3 is the best tool design from among the four models evaluated.