CFD Analysis of Flow Pattern in Electrochemical Machining Process

Abstract

CFD Electrochemical Machining process is a non-conventional machining process based on the Faraday‟s laws of electrolysis. It is an advanced machining process that has applications in fields like aerospace, medical technology etc. But still the ECM process has various shortcomings. For instance there are possibilities of passivation and boiling of the electrolyte due to complicated tool design and these results in very poor machining quality. Other problems include metal hydroxide sludge disposal etc. In the ECM process setup, the machines work in the pulsating mode and hence we don‟t get accurate results. Hence the CFD analysis is termed as the most accurate method to predict the flow. This project thesis aims at studying the flow pattern, current density, distribution pattern, pressure distribution, velocity profiles, turbulence etc. The required model was first designed in the CATIA software and then ANSYS –FLUENT software was used to analyze the problem statement. The geometric model consists of a circular iron work piece, a L-shaped tool made up of copper and the electrolyte used is 20% brine solution. The L-Shaped tool has a hole at its top through which electrolyte flows and hits the work piece. The model was stimulated and analyzed to find out the results.