Modeling and Simulation of the Electrochemical Machining (ECM) Material Removal Process for the Manufacture of Aero Engine Components

In order to increase the efficiency of jet engines hard to machine nickel-based and titanium-based alloys are in common use for aero engine components such as blades and blisks (blade integrated disks). Here Electrochemical Machining (ECM) is a promising alternative to milling operations. Due to lack of appropriate process modeling capabilities beforehand still knowledge based and a cost intensive cathode design process is passed through. Therefore this paper presents a multi-physical approach for modeling the ECM material removal process by coupling all relevant conservation equations. The resulting simulation model is validated by the example of a compressor blade. Finally a new approach for an inverted cathode design process is introduced and discussed.