JP Journal of Heat and Mass Transfer

© 2019 Pushpa Publishing House, Prayagraj, India

http://www.pphmj.com
http://dx.doi.org/10.17654/HM017010203
Volume 17, Number 1, 2019, Pages 203-214 ISSN: 0973-5763

CFD ANALYSIS OF ELECTROLYTE FLOW IN

ELECTROCHEMICAL MACHINING

Biswesh Ranjan Acharya, Sukanta Nayak and Amrit Mallick

Department of Mechanical Engineering
Centurion University of Technology and Management
Paralakhemundi, India

Abstract

Electrochemical machining (ECM), being a non-traditional machining

process, is basically used for machining hard to cut but electrically
conductive materials. In the presence of proper electrolyte and certain
difference of electric potential between tool and workpiece with
inter-electrode gap (IEG) causes chemical reaction on workpiece top
workpiece surface in ECM. Due to complex mechanism in IEG, only
some process parameters can be controlled simultaneously based upon
electrochemical machine specification. Theoretically, low operating
temperature and low IEG result in less thermal stress and mechanical
stress acting upon the workpiece top surface. In reality, tool-workpiece
contact occurs and temperature in IEG increases during experiment.
Such types of experimental failures motivate towards numerical
modeling for minimizing the defects. During electrochemical
machining, the eroded materials need to be removed from the
workpiece top surface to avoid undesired short circuits which requires
moderate electrolyte flow velocity on workpiece top surface. High
electrolyte flow velocity causes less MRR and low electrolyte flow
velocity causes passivation defects which results reduction in MRR.
Also, temperature of the electrolyte increases due to Joule’s heating
Received: December 7, 2018; Revised: January 8, 2019; Accepted: February 18, 2019
Keywords and phrases: inter-electrode gap (IEG), electrochemical machining (ECM),
electrolyte flow velocity, current density, computational fluid dynamics (CFD).
204 Biswesh Ranjan Acharya, Sukanta Nayak and Amrit Mallick
effect but it should not exceed its boiling temperature which may
result phase change of electrolyte. These irregularities can be analyzed
by constructing a computational fluid dynamics (CFD) model
using ANSYS 13.0 CFX software. Current density on workpiece
top surface, electrolyte velocity pattern and temperature profile of
electrolyte flow between the IEG are observed and decision is taken
for ideal tool design for extreme perfection in ECM.

Nomenclature

Cp Specific heat of the electrolyte, (J/kgk)

P Pressure
I Current, (A)
Q Heat generation in electrolyte in IEG
t Time, sec.
T Temperature, (K)
V Potential difference in IEG, (V)
v Velocity of electrolyte, (m/s)
Pkb and Pε b Influence of buoyancy forces

k0 Thermal conductivity at 300K, (W/mK)

k Thermal conductivity, (W/mK)

ρ Density electrolyte, (kg/m3)
α Coefficient of thermal conductivity of brine = 0.02

 Rate of velocity fluctuations dissipation, called as

turbulent eddy dissipation  m 2 / s3 

Pk Turbulent production due to viscous force

Sm Total body force

P Modified pressure
 CFD Analysis of Electrolyte Flow in Electrochemical Machining 205

1. Introduction

Basically, ECM process is used in offshore petroleum industries,

aerospace, defense and biomedical engineering. Electrochemical deburring,
electrochemical drilling, electrochemical polishing and electrochemical
grinding are certain modifications of ECM process. Capability to cut
electrically conductive material of low machinability at high material
removal rate, without inducing residual stress and tool wear has
distinguished electrochemical machining (ECM) from other non-traditional
machining processes. Electrolyte flow pattern in IEG is considered as one of
the important parameters. As low flow rate will form gas bubbles due to
boiling of electrolyte and high flow rate will result less MRR. So, precise
flow pattern is essential for improved productivity. Researchers tried various
modeling techniques for resembling accurate electrochemical machining.
Ratkovich et al. [1] developed a CFD model and discussed about two phase
flow in ECM. Dabrowski and Paczkowski [2] proposed a numerical model
for two dimensional electrolyte flow in the IEG during electrochemical
machining and observed the distribution of ECM parameters and compared
with the experimental data. Pattavanitch et al. [3] proposed a boundary
element method to simulate milling and turning operation and found it close
to experimental results. Purcar et al. [4] proposed a numerical method based
on the “marker” method for 3D simulation of electrode shape change in
ECM. He used an E-shaped tool and studied the current density distribution
on workpiece. Kozak et al. [5] developed software for simulation of ECM
process with universal spherical tool electrode and compared it with
experimental result. He also introduced neural network technique for
better process analysis, predicting the machined surface and optimization.
Labib et al. [6] introduced fuzzy logic controller to ECM for better control of
inter-electrode gap. Habib [7] deliberated various case studies examples for
the physical and mathematical models on the basis of which, simulation
process module is introduced computer-aided engineering system for ECM.
Wang et al. [8] carried out simulation work for calculating the planar solid
oxide fuel cells (SOFC) and discussed the influence of operating conditions
206 Biswesh Ranjan Acharya, Sukanta Nayak and Amrit Mallick

and anode structure on the performances of SOFC. More priority has given
for the shape change of the workpiece, whereas flow pattern of electrolyte is
not entertained. So, electrolyte flow pattern is vital and the objective of
this paper. Current density distribution and temperature of the electrolyte
during flow are also entertained during simulation. Present work proposes a
simulation of electrochemical process (ECM) in ANSYS 13.0 software using
CFX tool with magnetohydrodynamics (MHD) option for analyzing fluid
flow for different inlet velocities. There is heat generation in between
electrodes due to Joules heating effect and the cause of temperature rise of
electrolyte.

Figure 1. Combination of tool, electrolyte and workpiece after meshing.

2. Mathematical Model and Governing Equations

3D CFD model is constructed for flow pattern analysis of ECM for a

cylindrical tool and various parameters for inlet velocity 30m/s have been
studied. Only fluid part is considered for analysis on which governing
equations are functional. The k-ε model is used for solving this problem.
‘k’ is turbulent kinetic energy expressed as the variance of fluctuations
in velocity in m 2 / s 2 and ‘ε’ the rate at which the velocity fluctuations

dissipate, called as turbulent eddy dissipation in m 2 / s3. Figure 1 shows

the meshed model with named selections on which necessary boundary
conditions are applied:
 CFD Analysis of Electrolyte Flow in Electrochemical Machining 207

  u j 
(i) Continuity equation:   0.
t x j

(ii) Momentum equation:

ui  ui u j  P    u u j  

     e ff  i    Sm ,
t x j xi x j  
 jx xi  

where effective viscosity of turbulent flow, μ eff   t and turbulent

k2
viscosity, μ t  Cμ  ρ .


The values of k and ε are found out from the following turbulent kinetic
energy and dissipation rate equations as follows:
(iii) Turbulent kinetic energy and dissipation rate equations:

 k   u j     t  k 
       x   Pk    Pkb ,
t x j x j  k j

   u j      t   
     σ  x 
t x j x j   j


 P C  C1  C 2b  C1Pb ,
k k 1

 u u j  ui
where μ t   i   x .
 x j xi  j

(iv) Transport equation for heat conduction through the solid:

 C pT
    kT   S E .
t
User defined equations are also introduced for change in thermal
conductivity of electrolyte with temperature and heat generation in IEG.
Effect on temperature for 30m/s inlet velocity

Q  I 2 R  4.187  q    C p T  Ti .
208 Biswesh Ranjan Acharya, Sukanta Nayak and Amrit Mallick

Current density also varies with variation in the conductivity as:

k V  V 
J  .
y

Thermal conductivity of electrolyte varies with temperature as:

K  K 0 1  T  T300 K .

Assumptions in the analysis:

(a) Tool and workpiece are homogeneous in nature.

(b) The IEG is constant throughout the experiment.

(c) Tool and workpiece material property is assumed to be constant in

analysis.

(d) Heat is generated only in the IEG due to Joule’s heating effect.

(e) The electrolyte is in liquid state and no hydrogen gas is evolved.

(f) Material removal rate of workpiece depends only on current density.

Table 1. Material properties of tool, workpiece and electrolyte

Properties Brine Copper AISI D2 steel Air
Molar mass (kg/K-mol) 58.44 63.55 55.85 -
Density (kg/m )3
1050 8933 7860 -
Specific heat (J/kg-K) 3760 385 460 -
Dynamic viscosity (Pa-s) 0.001 - - -
Thermal conductivity (W/m-K) 0.6 401 80 -
Electrical conductivity (S/m) 8.43 5.96E+07 1E+07 -
Convection coefficient (W/m -K) 2
1000 - - 100

3. Simulation Process and Procedure

Boundary conditions
The inlet temperature of electrolyte is kept constant at 300K. The outlet
pressure of electrolyte is same as atmospheric pressure. Inlet velocity of
 CFD Analysis of Electrolyte Flow in Electrochemical Machining 209

electrolyte is varied 30m/s, 35m/s and 40m/s and comparison has been done
among them.

Convergence criteria
ANSYS CFX solver is used to converge the result. Time step of 30
second is used with maximum of 200 iterations per time step for simulation.
Convergence criteria are set to be 0.0001. Solution is said to be converged
either after completing 200 iterations or when converged to 0.0001. Figures
2-5 show the variation in the residuals for the properties of electrolyte like
turbulence (KE), heat transfer, momentum and mass and electromagnetism,
respectively, for inlet velocity of 30m/s.

Figure 2. Variation in the turbulence (KE) for fluid flow.

Figure 3. Variation in heat transfer for fluid flow.

210 Biswesh Ranjan Acharya, Sukanta Nayak and Amrit Mallick

Figure 4. Variation in the momentum, mass for fluid flow.

Figure 5. Variation in the electromagnetism for fluid flow.

4. Results and Discussion

Theoretically, fluid velocity in IEG reduced from inlet velocity as the

outer area is larger than inlet area. Loss in KE is observed due to first
contact of electrolyte with the workpiece surface. So, some variations
in the electrolyte flow distribution on workpiece surface are observed.
Temperature at the center of the workpiece top surface is lowest within the
IEG due to cold nature of electrolyte. But towards periphery, temperature
increases and flow velocity of electrolyte decreases due to Joule’s effect.
Figures 6-8 show the current density distribution on workpiece top surface,
temperature profile of electrolyte and electrolyte flow velocity on workpiece
top surface, respectively.
 CFD Analysis of Electrolyte Flow in Electrochemical Machining 211

Figure 6. Current density distribution on workpiece top surface at inlet

velocity 30m/s.

Figure 7. Effect on temperature at inlet velocity 30m/s.

Figure 8. Effect of electrolyte flow velocity on workpiece top surface at

30m/s inlet velocity.
212 Biswesh Ranjan Acharya, Sukanta Nayak and Amrit Mallick

Figure 9. Effect on temperature at 35m/s inlet velocity.

Figure 10. Effect of electrolyte flow velocity on workpiece top surface for
35m/s inlet velocity.

Figure 11. Effect on temperature for 40m/s inlet velocity.

 CFD Analysis of Electrolyte Flow in Electrochemical Machining 213

Figure 12. Effect of electrolyte flow velocity on workpiece top surface for
40m/s inlet velocity.

5. Conclusions

The required temperature distribution and electrolyte flow velocity

variation can be observed for inlet velocity of 35m/s and 40m/s from
Figures 9-12. While comparing the electrolyte flow velocity distribution and
temperature distribution for inlet velocities of 30m/s, it can be found that it
is in accordance with the earlier published papers. The proposed numerical
model provides an inexpensive and time saving alternative to study the
performance of machining of ECM process.

Acknowledgement

The authors thank the anonymous referees for their valuable suggestions
for the improvement of the manuscript.

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