A novel numerical strategy for modeling the moving boundary value problem of electrochemical machining

DOI10.1002/NME.7190MaRDI QIDQ6071384zbMATH OpenOpenAlexFDO

Authors Tim van der Velden, Stefanie Reese, Johanna Waimann

Publication date 23 November 2023

Published in International Journal for Numerical Methods in Engineering (Search for Journal in Brave)

Copyright license Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International

Full work available at URL https://arxiv.org/abs/2202.12704

zbMATH Keywords

electrochemical machiningfinite element methodmoving boundary value problem

Mathematics Subject Classification ID

Numerical methods for partial differential equations, boundary value problems (65Nxx)

Abstract: This work presents a new approach to efficiently model the cathode in the moving boundary value problem of electrochemical machining. Until recently, the process simulation with finite elements had the drawback of remeshing required by the changing surface geometries. This disadvantage was overcome by a novel model formulation for the anodic dissolution that utilizes effective material parameters as well as the dissolution level as an internal variable and, thereby, does not require remeshing. Now, we extend this concept to model arbitrarily shaped and moving cathodes. Two methodologies are investigated to describe the time varying position of the cathode. In the first approach, we change the electric conductivity of elements within the cathode and, in a second approach, we apply Dirichlet boundary conditions on the nodes of corresponding elements. For both methods, elements on the cathode's surface are treated with effective material parameters. This procedure allows for the efficient simulation of industrially relevant, complex geometries without mesh adaptation. The model's performance is validated by means of analytical, numerical and experimental results from the literature. The short computation times make the approach interesting for industrial applications.

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Cited in

(2)

• Comparison of Quasi-Stationary and Non-Stationary Solutions of Electrochemical Machining Problems Applying to Precision Cutting with Plate Electrode-Tool
• A comparative study of micromorphic gradient-extensions for anisotropic damage at finite strains

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