Modeling of Multi-Phase Flow in Electro-Chemical Machining: One-Way Coupling Versus Two-Way Coupling

Electro-Chemical Machining (ECM) is an advanced machining technology. It has been applied to 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, CFD is considered to be a powerful tool in the near future. However, the numerical method that can satisfactorily predict ECM process has not been established because of the complex flow natures. In the present study, we investigate the modeling of the two-phase flow (i.e. fluid and hydrogen bubbles) in ECM process. First, we present two models to calculate flow fields in ECM process. One is based on one-way coupling method, neglecting the effect from gas-phase to liquid-phase. The other takes account of the interaction between gas and liquid phases, namely two-way coupling method. In the later method, assuming that electrolyte and hydrogen bubbles have same velocity, we simplified the governing equations with Low Mach number approximation. We simulated ECM process for a flat plate channel configuration. And, we verified the present models by comparing the numerical result with the experimental data.Copyright © 2007 by ASME