Two- Phase Simulation of Electrochemical Machining

Abstract

The machining accuracy of Electrochemical Machining (ECM) is affected by the temperature and bubbles. The effect of bubbles in the simulation can be considered by first calculating the volume fraction of gas distribution (using bubbly flow approximation in this study) and then approximating the effective conductivity in the inter-electrode gap by using Bruggemann equation. Since, Bruggemann equation is independent of bubble diameter and distribution, its dependency on that was investigated in this study. Moreover, the effect of the bubbles generated on the machining accuracy of the axi-symmetric work piece with different flow rates was also investigated.