抄録
Electrochemical Machining (ECM) is an advanced machining technology and has been applied to highly specialized fields, such as aerospace, aeronautics, and medical industries. However, some problems remain to be solved. The efficient tool-design, electrolyte processing, and disposal of metal hydroxide sludge are typical problems. To solve such problems, CFD is thought to have potential as a powerful tool. However, a numerical method that can satisfactorily predict the ECM process has not been established because of the complex flow natures. In the present study, we presented a new model to calculate the flow fields in an ECM process. This model is based on a two-way coupling method, taking the interaction between gas and liquid phases into account. In this coupling method, we assumed that electrolyte and generated hydrogen bubbles over a,cathode surface have the same velocity. Therefore, we could simplify the governing equations. Since the flow field had a non-uniform density distribution due to hydrogen bubbles, a low Mach number approximation was applied to solve the pressure Poisson equation. We simulated ECM process for a flat plate channel configuration. And, we verified the present model by comparing the numerical result with the experimental data. The simulation results show good agreements with experimental data in the view of gap height.
