Multiphysics Based Tool Design for Electrochemical Machining

We propose to develop a multiphysics design platform to predict optimal electrochemical machining (ECM) tool shape using commercially available Multiphysics simulation software in conjunction with well-defined validation experiments. Prof. K.P. Rajukar, Director of the Center for Nontraditional Manufacturing Research at the University of Nebraska will serve as a subcontractor. ECM is a manufacturing technology that allows metal to be precisely removed by electrochemical oxidation and dissolution into an electrolyte solution. As described by Prof. Rajukar’s keynote paper to the International Academy for Production Engineering, ECM has numerous advantages relative to traditional machining including 1) applicability to hard and difficult to cut materials, 2) no tool wear, 3) high material removal rate, 4) smooth bright surface finish, and 5) production of parts with complex geometry. However, Prof. Rajurkar noted five research challenges preventing wider adoption of ECM. The proposed Multiphysics tool design platform for prediction of optimal ECM tool shape with minimal empirical iteration addresses the two remaining research challenges defined by Prof. Rajukar: (1) tool design and (2) machining accuracy. Phase II will continue the development of an ECM Multiphysics-based tool design platform in conjunction with confirming die-sink ECM tests to accurately predict work piece geometry and surface finish.