Multiphysics Simulation of ECM for the Machining of AL-SIC Composites

Abstract

Al-SiC composite is one of the widely used MMC in various application. It has some specific properties like high thermal conductivity and high strength to weight ratio which tends to use it in some high-end applications like microelectronics, aerospace and, automobile, etc. Inspite of its exceptional properties, Al-SiC is also one of the difficult composites to machine. So machining of Al-SiC composite with a conventional process would face challenges. Unconventional process like electrochemical machining process offers a better alternative in generating accurate complex geometries in difficult to machine material. By varying the parameters of ECM process the material removal of Al-SiC can be varied. Further, the material removal from ECM process is also influenced by the composition of Al-SiC. In this paper, multiphysics models have been developed in COMSOL to characterize the Electrochemical process to study the material removal of Al-SiC. The parametric study is also performed to study the influence of machining parameters on material removal. This work can provide details on the ECM process for the machining of Al-SiC.