Simulation of the magnetic field assisted electrochemical machining

Electrochemical machining (ECM) is an unconventional manufacturing method based on the anodic dissolution of the metal workpiece material. A superimposed magnetic field causes additional body forces within the working gap influencing the electrolyte convection and consequently afecting the electrochemical kinetics and gas transport. In this study, a multiphysics simulation model was built to analyze the interactions between the magnetic field characteristics, the convective heat- and charge-transport in the working gap and the electrochemical workpiece shaping. Therefore, the Lorentz force and Kelvin force were considered. In addition, machined geometries and surface properties were measured and related to the simulation findings.