Research in Tool Shape Optimization for Electrochemical Machining

Electrochemical Machining (ECM) is controllable and scalable, harnessing corrosion to deliver the unique capability of machining complex shapes comprising very hard materials in relatively benign electrolytes. ECM tools have traditionally been designed by trial and error, which is time-consuming and expensive, making the process optimization and project management very difficult. The ECM process itself is extremely complex, involving changing potential and current density fields, thermal effects, reacting multi-component flow and gas evolution, combined with the dynamics of tool motion.Objectives of Phase 1 are to demonstrate the feasibility for using FEA (Finite Elements Analysis) multi-physics software to determine, upfront, the necessary shape of an ECM cathode tool to achieve a target component shape and finish. Corrdesa will leverage expertise in corrosion simulation and computational fluid dynamics (CFD) to deliver the envisioned end state of a generic, software platform able to take as input, material properties and specified target geometries and deliver as output the required ECM cathode tool shape and operating conditions.To demonstrate the accuracy of our cathode tool design software, we will build a bench scale ECM rig and the designed cathode tool to manufacture a first-part geometry comparing its shape and surface finish with the targeted criteria.