Accelerated electrochemical machining tool design via multiphysics modeling

B. Skinn, T. D. Hall, S. Snyder, K. P. Rajurkar, E. J. Taylor

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

A significant challenge preventing wider industrial adoption of electrochemical machining (ECM) is the lack of efficient, a priori means for selection of a tool design to achieve a target part shape with high accuracy. Tight coupling among the numerous physical phenomena active in industrial electrochemical processes confounds the simplification approaches available in other contexts. Recent developments in computational hardware and software allow simultaneous solution of the relevant governing equations, potentially enabling practical tool design methods by solution of the inverse electric field problem.'' This paper discusses recent work comparing primary current distribution simulations to indentations fabricated by ECM of steel panels. Good agreement was obtained for a subset of the tests performed. The results highlight the importance of including additional physical phenomena such as flow effects and electrochemical polarization in order to obtain more accurate simulations. In particular, the current efficiency of the metal dissolution reaction likely must be considered.

Original languageEnglish (US)
Title of host publicationSelected Proceedings from the 231st ECS Meeting New Orleans, LA - Spring 2017
PublisherElectrochemical Society Inc.
Pages963-979
Number of pages17
Edition11
ISBN (Electronic)9781607685395
DOIs
StatePublished - Jan 1 2017
Event231st ECS Meeting - New Orleans, United States
Duration: May 28 2017Jun 1 2017

Publication series

NameECS Transactions
Number11
Volume77
ISSN (Print)1938-6737
ISSN (Electronic)1938-5862

Other

Other231st ECS Meeting
CountryUnited States
CityNew Orleans
Period5/28/176/1/17

Fingerprint

Machining
Indentation
Dissolution
Electric fields
Polarization
Hardware
Steel
Metals

ASJC Scopus subject areas

  • Engineering(all)

Cite this

Skinn, B., Hall, T. D., Snyder, S., Rajurkar, K. P., & Taylor, E. J. (2017). Accelerated electrochemical machining tool design via multiphysics modeling. In Selected Proceedings from the 231st ECS Meeting New Orleans, LA - Spring 2017 (11 ed., pp. 963-979). (ECS Transactions; Vol. 77, No. 11). Electrochemical Society Inc.. https://doi.org/10.1149/07711.0963ecst

Accelerated electrochemical machining tool design via multiphysics modeling. / Skinn, B.; Hall, T. D.; Snyder, S.; Rajurkar, K. P.; Taylor, E. J.

Selected Proceedings from the 231st ECS Meeting New Orleans, LA - Spring 2017. 11. ed. Electrochemical Society Inc., 2017. p. 963-979 (ECS Transactions; Vol. 77, No. 11).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Skinn, B, Hall, TD, Snyder, S, Rajurkar, KP & Taylor, EJ 2017, Accelerated electrochemical machining tool design via multiphysics modeling. in Selected Proceedings from the 231st ECS Meeting New Orleans, LA - Spring 2017. 11 edn, ECS Transactions, no. 11, vol. 77, Electrochemical Society Inc., pp. 963-979, 231st ECS Meeting, New Orleans, United States, 5/28/17. https://doi.org/10.1149/07711.0963ecst
Skinn B, Hall TD, Snyder S, Rajurkar KP, Taylor EJ. Accelerated electrochemical machining tool design via multiphysics modeling. In Selected Proceedings from the 231st ECS Meeting New Orleans, LA - Spring 2017. 11 ed. Electrochemical Society Inc. 2017. p. 963-979. (ECS Transactions; 11). https://doi.org/10.1149/07711.0963ecst
Skinn, B. ; Hall, T. D. ; Snyder, S. ; Rajurkar, K. P. ; Taylor, E. J. / Accelerated electrochemical machining tool design via multiphysics modeling. Selected Proceedings from the 231st ECS Meeting New Orleans, LA - Spring 2017. 11. ed. Electrochemical Society Inc., 2017. pp. 963-979 (ECS Transactions; 11).
@inproceedings{03f390fe582c4938ae66ac7568f7b013,
title = "Accelerated electrochemical machining tool design via multiphysics modeling",
abstract = "A significant challenge preventing wider industrial adoption of electrochemical machining (ECM) is the lack of efficient, a priori means for selection of a tool design to achieve a target part shape with high accuracy. Tight coupling among the numerous physical phenomena active in industrial electrochemical processes confounds the simplification approaches available in other contexts. Recent developments in computational hardware and software allow simultaneous solution of the relevant governing equations, potentially enabling practical tool design methods by solution of the inverse electric field problem.'' This paper discusses recent work comparing primary current distribution simulations to indentations fabricated by ECM of steel panels. Good agreement was obtained for a subset of the tests performed. The results highlight the importance of including additional physical phenomena such as flow effects and electrochemical polarization in order to obtain more accurate simulations. In particular, the current efficiency of the metal dissolution reaction likely must be considered.",
author = "B. Skinn and Hall, {T. D.} and S. Snyder and Rajurkar, {K. P.} and Taylor, {E. J.}",
year = "2017",
month = "1",
day = "1",
doi = "10.1149/07711.0963ecst",
language = "English (US)",
series = "ECS Transactions",
publisher = "Electrochemical Society Inc.",
number = "11",
pages = "963--979",
booktitle = "Selected Proceedings from the 231st ECS Meeting New Orleans, LA - Spring 2017",
edition = "11",

}

TY - GEN

T1 - Accelerated electrochemical machining tool design via multiphysics modeling

AU - Skinn, B.

AU - Hall, T. D.

AU - Snyder, S.

AU - Rajurkar, K. P.

AU - Taylor, E. J.

PY - 2017/1/1

Y1 - 2017/1/1

N2 - A significant challenge preventing wider industrial adoption of electrochemical machining (ECM) is the lack of efficient, a priori means for selection of a tool design to achieve a target part shape with high accuracy. Tight coupling among the numerous physical phenomena active in industrial electrochemical processes confounds the simplification approaches available in other contexts. Recent developments in computational hardware and software allow simultaneous solution of the relevant governing equations, potentially enabling practical tool design methods by solution of the inverse electric field problem.'' This paper discusses recent work comparing primary current distribution simulations to indentations fabricated by ECM of steel panels. Good agreement was obtained for a subset of the tests performed. The results highlight the importance of including additional physical phenomena such as flow effects and electrochemical polarization in order to obtain more accurate simulations. In particular, the current efficiency of the metal dissolution reaction likely must be considered.

AB - A significant challenge preventing wider industrial adoption of electrochemical machining (ECM) is the lack of efficient, a priori means for selection of a tool design to achieve a target part shape with high accuracy. Tight coupling among the numerous physical phenomena active in industrial electrochemical processes confounds the simplification approaches available in other contexts. Recent developments in computational hardware and software allow simultaneous solution of the relevant governing equations, potentially enabling practical tool design methods by solution of the inverse electric field problem.'' This paper discusses recent work comparing primary current distribution simulations to indentations fabricated by ECM of steel panels. Good agreement was obtained for a subset of the tests performed. The results highlight the importance of including additional physical phenomena such as flow effects and electrochemical polarization in order to obtain more accurate simulations. In particular, the current efficiency of the metal dissolution reaction likely must be considered.

UR - http://www.scopus.com/inward/record.url?scp=85030751458&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=85030751458&partnerID=8YFLogxK

U2 - 10.1149/07711.0963ecst

DO - 10.1149/07711.0963ecst

M3 - Conference contribution

AN - SCOPUS:85030751458

T3 - ECS Transactions

SP - 963

EP - 979

BT - Selected Proceedings from the 231st ECS Meeting New Orleans, LA - Spring 2017

PB - Electrochemical Society Inc.

ER -