Multiphysics simulation of electrochemical machining process for three-dimensional compressor blade

Electrochemical machining (ECM) is an advanced machining technology. It has been applied in highly specialized fields such as aerospace, aeronautics, and medical industries. However, it still has some problems to be overcome. The efficient tool design, electrolyte processing, and disposal of metal hydroxide sludge are the typical issues. To solve such problems, computational fluid dynamics is expected to be a powerful tool in the near future. However, a numerical method that can satisfactorily predict the electrolyte flow has not been established because of the complex nature of flows. In the present study, we developed a multiphysics model and the numerical procedure to predict the ECM process. Our model and numerical procedure satisfactorily simulated a typical ECM process for a two-dimensional flat plate. Next, the ECM process for a three-dimensional compressor blade was simulated. Through visualization of the computational results, including the multiphase flow, and thermal and electric fields between the tool and the blade, it is verified that the present model and numerical procedure could satisfactorily predict the final shape of the blade.