Development of simulation software package for nano-pulsed electrochemical micro machining

The pulsed electrochemical micromachining process simulation is described, on a axisymmetric geometry which reflects a real case tool-electrolyte-workpiece system. It is simulated by modeling the electrical double layer, at the electrode-electrolyte interface, as a parallel RC circuit which charges and discharges as function of nano-second pulses. To achieve this, a potential model is proposed which solves the Laplace equation in combination with the capacitor and Butler-Volmer equations. During ultrashort pulses, the metal dissolution reactions are confined through this setup, to electrode regions where the tool-workpiece gap is the smallest. The current density in that area reaches millions of amperes per square meter and translates into fast removal of the material.