CFD Analysis of L-Shaped ECM Tool

Abstract

In electrochemical machining, due to improper tool design of complicated shapes, there are chances of passivation of electrolyte that cause poor machining. Predicting the flow pattern is also important to prevent boiling tendency of electrolyte is due to overheating of electrolyte. This research work is an endeavour to optimise the design of L-shaped tool and to study the flow pattern, current density distribution, velocity profile and temperature pattern by CFD analysis using ANSYS-CFX software. The model is simulated with various inlet velocities and the major findings are: the maximum temperature of electrolyte in inter electrode gap decreases with increase in inlet velocity. The current density and material removal rate has increasing tendency with respect to increase in inlet velocity. The tendency of passivation decreases with increasing inlet velocity.