电解加工中材料溶解有效建模的新方法
A novel approach for the efficient modeling of material dissolution in electrochemical machining
摘要：
这项工作提出了一种新的方法，有效地模拟电化学加工中的阳极溶解。早期的建模方法采用严格的空间离散化的阳极表面，这是与一个重新网格化的过程中的每一个时间步。此外，所提出的模型是建立在有效的材料参数。因此，它允许使用恒定的网格用于整个模拟，从而降低了计算成本。基于法拉第电解定律，引入了有效溶解水平，它描述了溶解体积与其相应参考体积的比值。该内部变量允许对复杂的溶解过程进行建模，而无需通过控制有效材料参数进行计算上昂贵的重新网格化。此外，充分耦合的热电问题被认为是其线性化和数值实现。该模型显示出良好的协议与分析和实验验证的例子，产生现实的结果。此外，脉冲电化学加工过程的模拟产生与特定累积电荷相关的表面粗糙度的过程签名。数值算例验证了模拟的计算效率和准确的建模质量。
英文摘要：
This work presents a novel approach to efficiently model anodic dissolution in electrochemical machining. Earlier modeling approaches employ a strict space discretization of the anodic surface that is associated with a remeshing procedure at every time step. Besides that, the presented model is formulated by means of effective material parameters. Thereby, it allows to use a constant mesh for the entire simulation and, thus, decreases the computational costs. Based on Faraday's law of electrolysis, an effective dissolution level is introduced, which describes the ratio of a dissolved volume and its corresponding reference volume. This inner variable allows the modeling of the complex dissolution process without the necessity of computationally expensive remeshing by controlling the effective material parameters. Additionally, full coupling of the thermoelectric problem is considered and its linearization and numerical implementation are presented. The model shows good agreement with analytical and experimental validation examples by yielding realistic results. Furthermore, simulations of a pulsed electrochemical machining process yield a process signature of the surface roughness related to the specific accumulated electric charge. The numerical examples confirm the simulation's computational efficiency and accurate modeling qualities.
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