Multiphysics Based Tool Design for Electrochemical Machining

In the program Efficient Tool Design for Electrochemical Machining, we propose to develop a 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. Rajurkar, Distinguished Professor of Industrial Engineering and Director of the Center for Nontraditional Manufacturing Research at the University of Nebraska will serve as a consultant to the program. ECM is a manufacturing technology that allows metal to be precisely removed by electrochemical oxidation and dissolution into an electrolyte solution. As described in Prof. Rajukars 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.In spite of these advantages, Prof. Rajurkar noted five research challenges preventing the wider adaptation 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.