Multi-time scale simulation of pulse electrochemical machining process with multi-physical model
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ORIGINAL ARTICLE
Multi-time scale simulation of pulse electrochemical machining process with multi-physical model Chen Yuanlong 1 & Jiang Lijun 1 & Fang Ming 2 & Zhang Juchen 1 Received: 14 March 2020 / Accepted: 28 August 2020 / Published online: 5 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract To determine the relationship between the pulse current and the physicochemical properties of multi-time scales, a method of multi-time scale simulation is introduced to investigate multi-time scale evolution of temperature and void fraction in PECM process. A multi-time scale iterations method is introduced to reduce computation time of multi-time scale simulation. Simulation results indicate that the method is efficient and pulse current can make the PECM process more stable. Experimental results show that the multi-time scale simulation results can well match the actual machining results, especially in the middle section of the workpiece. Keywords Pulse electrochemical machining . Multi-physical model . Multi-time scales . Temperature . Void fraction
1 Introduction Electrochemical machining (ECM) is a non-contact controllable dissolution process. Due to the unique processing advantages such as regardless of workpieces physical characteristics, ECM has been applied widely in the aerospace, automotive, and national defense industries [1–3]. With the advent of pulse electrochemical machining (PECM) in the late 1980s, pulsed current instead of the continuous current was used in ECM process and has been found to improve the processing accuracy of ECM [4]. However, it is difficult to determine the relationship between the pulse current and the physicochemical properties of multi-time scales due to micro-time scale characteristics of the pulse current. Therefore, in practice, a large number of experiments are carried out before process parameters are mature, which increases the cost of process and limits the application scope of PECM.
* Fang Ming [email protected] 1
School of Mechanical Engineering, Hefei University of Technology, Hefei 230009, China
2
School of Mechanical and Automotive Engineering, Anhui Polytechnic University, Wuhu 241000, China
To solve the above problems, more and more attention has been paid to the simulation of PECM processes. Kozak et al. [5–7] used an approximate method that a series of pulse were represented by one pulse to calculate the temperature distribution in PECM process but ignoring heat transfer in the electrodes and the influence of void fraction. Smets et al. [8] investigated the influence of electrodes on temperature evolution and drew a conclusion that temperature evolution in massive electrodes exists extra time scales. Then, Smets et al. [9–11] introduced averaging algorithm of heat sources to solve the problem of large amount of simulation calculations but made an assumption that the geometry stays the same. Chen et al. [12] introduced a simplified algorithm to calculate the shape change of the electrodes in PECM process but ignoring the in
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