Simulation of the electrode shape change in electrochemical machining based on the level set method

Department of Electrical Engineering, Technical University of Cluj-Napoca, G. Baritiu Street 26-28, 400020, Cluj-Napoca, Romania

^a e-mail: marius.purcar@et.utcluj.ro

Received: 8 December 2011
Revised: 20 February 2012
Accepted: 27 February 2012
Published online: 23 March 2012

Abstract

This paper proposes a generally applicable numerical algorithm for the simulation of two dimensional electrode shape changes during electrochemical machining processes. The computational model consists of two coupled problems: an electrode shape change rate analysis and a moving boundary problem. The innovative aspect is that the workpiece shape is computed over a number of predefined time steps by convection of its surface with a velocity proportional and in the direction of the local electrode shape change rate. An example related to the electrochemical machining of a slot in a stainless steel plate is presented here to demonstrate the strong features of the proposed method.