Stray current attack and stagnation zones in electrochemical drilling

Electrochemical drilling (ECD) is a complex phenomenon involving two phase fluid dynamics, unsteady state heat transfer, mass transfer, electrochemistry etc. between moving boundaries. Anode (work) shape prediction models, therefore, are complicated and incomplete. These models are incomplete because they ignore the analysis of the stray current attack zone and stagnation zone. A modified anode shape prediction model has been proposed. It predicts the work (anode) profile in all the five zones, i.e, stagnation, front, transition, side, and stray current attack. Comparison of computed and experimental anode profiles reveals a satisfactory agreement between the two.