Design Optimization of The Formation of Boss or Ridge and Passivation of Electrolyte Flow in ECM Process Using CFD Simulation 05 July

IJBSTR RESEARCH PAPER VOL 1 [ISSUE 7] JULY 2013
ISSN 2320 6020
Design Optimization of the Formation of Boss or Ridge and

Passivation of Electrolyte Flow in ECM Process Using CFD
Simulation
Krishna Mohan Singh and R. N. Mall
ABSTRACT: The main objective of the paper is to investigate the flow pattern of electrolyte in the flow path for the initial work
shape conforms to the tool shape, the machining process itself causes the formation of boss or ridge in the work piece; this helps in a
proper distribution of the electrolyte flow. A tool with an electrolyte supply slot is simple to manufacture, but such a slot leaves small
ridges on the work. And slot design to avoid development of passive area
KEYWORDS: ECM, Electrolyte, CFD CODE, Boss and Ridge Formation, Boss and Ridge Formation.
1 INTRODUCTION
Electrochemical machining (ECM) has seen a resurgence of
industrial interest within the last couple of decades due to its
many advantages such as no tool wear, stress free and smooth
surfaces of machined product and ability to machine complex
shape in electrically conductive materials, regardless of their
hardness. It has been applied in diverse industries such as
aerospace, automotive and electronics, to manufacture airfoils
and turbine blades, die and mold, artillery projectiles, surgical
implants and prostheses, etc. Moreover with recent advances
in machining accuracy and precision, based on the
development of advanced electrochemical metal-removal
processes, demonstrate that the ECM can be effectively used
for micromachining components in the electronics and
precision industries.
Fig.1: Formation of boss and ridge on machined surface

1.2 Experimental Set-Up and Principle of ECM
1.1 Scope of the Work

1. To simulate the electrolyte flow from Boss and
ridge formation and discuss the results
2. To simulate the electrolyte flow for different
velocity range and result discussion based on CFD
results
3. To investigate the pressure distribution (contours),
temperature distribution (contours), velocity vectors
etc. during the flow path of electrolyte
Krishna Mohan Singh and R. N. Mall
Department of Mechanical Engineering
M.M.M. Engineering College Gorakhpur
273010 (UP) India
Email: kmssh1988@gmail.com and
mall_rn@radiffmail.com
ECM works on the principle of Faradays law i.e. when two

conductive electrodes are placed in an electrolyte maintained
at low potential difference then there is discharge of electrons
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taking place. When the current is switched on, the electrolyte
(NaCl+H2O) gets ionised according to the following
relationshipNaCl Na++ ClH2O H++ OHAs hydrogen ions reach the cathode (tool), they combine with
free electrons resulting into evolution of H2 gas.
2H++ 2e- H2
Assume that pure iron is being machined by this process,
reactions that would occur are
2Na++ 2OH- = 2NaOH &
Fe2++2Cl--= FeCl2
2NaOH + FeCl2 = 2NaCl + Fe(OH)2
Thus in ECM of iron, using NaCl as the electrolyte, iron is
removed as Fe(OH)2 and sodium chloride is recovered back.
The iron hydroxide produced during the process must be
removed continuously from the electrolyte by filtration before
it is re-circulated.
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2. It carries the current between the tool and the work-piece.
3. It removes the products of machining from the cutting
region.
For ECM process the electrolytes must have high electrical
conductivity, low toxicity and low corrosiveness. The
electrolyte is pumped at about 14 Kg/cm2 and at speed
ranging from 5-50 m/s.
1.3.2 SIZE, SHAPE AND MATERIAL OF THE TOOL:
The tool must match the required shape of the work
piece depending on the material and the profile to be
produced. Tool materials used in ECM must have
good thermal and electrical conductivity; corrosion
resistance must be highly machinable and should be
stiff enough to withstand the electrolytic pressure
without vibrating.
SERVO SYSTEM
TOOL FEED RATE:
TEMPERATURE CONTROL:
MATERIAL REMOVAL RATE:
TOOL DESIGN:
SURFACE FINISH:
PUMPS:
FILTRATION AND STORAGE TANKS:
VALVES AND PIPING
Fig 2: Before machining
Fig 3: After machining

It is to be noted that in ECM process, the machining gap size
increases as the metal is removed. The larger gap leads to a
decrease in the metal removal rate. Therefore to maintain a
constant gap between the tool and the work piece, the cathode
(tool) should be advanced towards the anode (work) at the
same rate at which the metal is removed.
1.3 ECM MACHINE PARAMETERS
Fig.4 Schematic diagram to show the electrolyte flow
1.3.1 ELECTROLYTE
The electrolyte is very essential parameter for the electrolytic
process to work. In ECM process the electrolyte is used to
perform three main functions:1. It dissipates heat produced in the operation.
ECM process is quite similar in concept to electrical discharge

machining with a high current passed across its inter-electrode
gap through the electrolyte, a material removal process having
a negatively charged electrode (cathode-tool), conductive fluid
(electrolyte), and a conductive work-piece (anode), however in
ECM there is no tool wear. The ECM cutting tool is guided
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IJBSTR RESEARCH PAPER VOL 1 [ISSUE ] JULY 2013
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along the desired path very close to the work but it does not
touch the piece. Unlike EDM however, no sparks are created.
creation and manipulation of highly complex geometries and

mesh generation.
1.4 SPECIFICATIONS OF ECM
2.1 Selection of Solver
TABLE 1 ECM specifications
Pressure based or segregated solver is selected for solving

incompressible flow through the electrolyte path with implicit
scheme with cell based approach. 2D approach is used.2.2
Boundary Conditions
For solving any problem using numerical technique, it is first
step to apply appropriate and exact boundary conditions,
which defines the problem, in order to get the solution of that
specific problem. A solution is always sensitive to the inlet
boundary conditions; a great care is needed to be taken while
imposing the boundary condition.
After meshing the domain, it is imported to the solver
FLUENT version 6.3.26.The dimensions of the domain
properly scaled (conversion from cm to meter). The pressure
based or segregated solver is used for the current problem.
Primarily the standard k- model is used for viscous
modelling, after a converged result it is switched over to other
model to find out the appropriate viscous model suitable for
the present case.
2.3 Boundary Conditions:
the inlet of the tool
VELOCITY_INLET- is given at
Pressure outlet is given at the outlet of the electrolyte flow

WALL is selected for all other sections
FLUID- is specified as continuum type boundary condition.
Technical Data
Tool area - 30 mm2.
Cross head stroke - 150 mm.
Job holder - 100 mm opening X 50 mm depth X 100
mm width.
Tool feed motor - DC Servo type.
CFD CODE
2.4 Properties of Electrolyte used:

Density of electrolyte () = 1050 kg/m3
Dynamic viscosity of water () = 0.001 kg/m-sec.
2.5 Calculations:
Electrolyte flow in the ECM flow path can be recognized by
calculating Reynold's number, which is given as (using
equation 4.1)
There are several commercial CFD codes such as CFX,

FLOWTRAN, FLUENT, STAR CD, PHOENICS etc.
which are available for analyzing the complex flows.
But in the present investigation the commercial CFD
code FLUENT version 6.2.26 is to be used and for
modelling and Meshing GAMBIT version 2.3.16 is
to be used.
RN = Reynoldss number
2.0 Geometric Modelling of Flow Domain
V = Mean Velocity of flow
The geometry and flow domain of the electrolyte flow path is

modelled by using GAMBIT 2.3.16 software. The geometry
modelling and meshing tool of GAMBIT allows us for
D = diameter of tubular flow
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= Kinematics Viscosity (Dynamic viscosity / Density)

= Fluid density
When the Reynolds No. (RN) is less than 2000 fluid flow
results in laminar flow and if the Reynolds No. (RN) is more
than 2000 turbulent flow occurs.
Calculation for inlet velocity=5m/s
For Electrolyte
Density of fluid () = 1050 kg/m3
Dynamic viscosity of water () = 0.001 kg/m-sec.
Inlet diameter of electrolyte=2mm=0.002m
Inlet velocity=5 m/s
Substituting above values in equation 1.1
RN=
1050 .002 5
0.001
Figure 4.166: Contours of static pressure for electrolyte flow

over boss formation with corner radius of 0.7mm at inlet
velocity, V=5m/s [ k model with standard wall functions]
=10500 (turbulent flow)
Discussion on Boss and Ridge Formation

Fig.4.166 to fig. 4.169 shows the pressure contours, velocity
contours, velocity vectors and path lines for electrolyte flow
over boss formation with corner radius of 0.7mm at inlet
velocity, V=5m/s using k model with standard wall
functions.
It can be observed that boss formation produces negative
pressure inside flow path and vortex formation near bottom
corners if corner radius is not selected proper.
Similarly Fig.4.170 to fig. 4.173 shows the pressure contours,
velocity contours, velocity vectors and path lines for
electrolyte flow over boss formation with corner radius of
0.7mm at inlet velocity, V=5m/s using k model with
standard wall functions. It can be observed that for Ridge
formation there is no negative pressure and vortex formation
inside flow path, hence allows smooth flow of electrolyte.
Discussion on passivation due to flow interruption
Fig. 4.174 and Fig. 4.175 shows that if the flow geometry is
like the figure shown in fig. 4.174 then electrolyte cannot
approach the entire area of the geometry hence creating
passive area. To avoid or reduce this passive area formation
the geometry should be designed like shown in fig. 4.176 and
fig. 4.177
Figure 4.167: Contours of velocity magnitude for electrolyte

flow over boss formation with corner radius of 0.7mm at inlet
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ISSN 2320 6020
Figure 4.168: velocity vectors for electrolyte flow over boss

formation with corner radius of 0.7mm at inlet velocity,
V=5m/s [ k model with standard wall functions]
Figure 4.170: Contours of static pressure for electrolyte flow

over ridge formation with corner radius of 0.7mm at inlet
Figure 4.169: path lines for electrolyte flow over boss

Figure 4.171: Contours of velocity magnitude for electrolyte

flow over ridge formation with corner radius of 0.7mm at inlet
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Figure 4.172: velocity vectors for electrolyte flow over ridge

Figure 4.174: Contours of velocity magnitude for passivation

due to flow interruption at inlet velocity, V=5m/s [ k
model with standard wall functions]
Figure 4.173: path lines for electrolyte flow over ridge

Figure 4.175: velocity vectors for passivation due to flow

interruption at inlet velocity, V=5m/s [ k model with
standard wall functions]
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3.1:
CONCLUSIONS
For the present study simulations have been done by making
2-D geometric models of electrolyte flow path.
Literature suggest that cavitations, stagnation and vortex
formation in the flow path should be avoided since these lead
to a bad surface finish, hence for better surface finish
cavitations, stagnation and vortex formation should be
completely eliminated from the electrolyte flow path.
Simulation has also been done for boss and ridge formation
and results shows that these formations help in a proper
distribution of the electrolyte flow. Due to these formations no
stagnation of electrolyte occurs in the flow path which leads to
better surface finish.
From simulation results it is obvious that ridge formation is
more advantageous than boss formation.
Simulation has also been done for passivation due to flow
interruptions and simulation results suggest that proper tool
design is necessary to avoid or reduce the passive area
formation so that the electrolyte can reach to every portion of
the surface of work.
Figure 4.176: Contours of velocity magnitude for slot design

to reduce or avoid development of passive area at inlet
3.2:
SUGGESTIONS FOR FUTURE WORK
There is always a future scope for further investigation. The
following suggestions may be useful for future work related to
simulation work
1. Same work can be extended for electrolyte flow path
by making axis symmetric and 3d models and results
can be compared
2. This work can be extended for other electrolytes and
by using user defined functions.
3. Work can also be extended by using other parameters
like moving tool or wall functions, varying gap
between tool and work etc.
REFERENCES
Figure 4.177: velocity vectors for slot design to reduce or

avoid development of passive area at inlet velocity, V=5m/s [
k model with standard wall functions]
1.
Ghosh and Mallik, Manufacturing Science, 2nd

edition, EWP press, 2010
2.
Dr. D. S. Bilgi and Mr. P. V. Jadhav, Enhancement of

surface finish of Pulse Electrochemically Machined
(PECM)
surface
using
rotating
electrode.
International Journal of Computer Communication
and Information System (IJCCIS) Vol2. No1.
ISSN: 09761349 July Dec 2010
3.
J. Kozak, Mathematical model for computer

simulation of electrochemical machining processes,
Journal of Material Processing Technology 76(1998)
170-175.
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4.
5.
6.
7.
8.
ISSN 2320 6020
Jerzy
kozak,
Antoni
F.
Budzynski,
PiotrDomanowski,
Computer
simulation
electrochemical shaping (ECM-CNC) using a
universal tool electrode. Journal of Material
Technology 76(1998) 162-164.
www.sciencedirect.com
www.nitrkl.ac.in
Computational fluid dynamics by H.Choi, H.G.Choi
and J.Y.YOO (EDS).
Text book of Production technology HMT.
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Design Optimization of The Formation of Boss or Ridge and Passivation of Electrolyte Flow in ECM Process Using CFD Simulation 05 July

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Design Optimization of The Formation of Boss or Ridge and Passivation of Electrolyte Flow in ECM Process Using CFD Simulation 05 July

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IJBSTR RESEARCH PAPER VOL 1 [ISSUE 7] JULY 2013

ISSN 2320 6020