Electrochemical machining - experimental characterization and development of an efficient dissolution prediction methodology

• Applicants: Dr.-Ing. Andreas Klink; Professorin Dr.-Ing. Johanna Waimann; Professorin Dr.-Ing. Daniela Zander
• Subject Area: Mechanics
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 560492325

Electrochemical machining (ECM) is a non-conventional manufacturing process. The metallic tool surface to be machined is removed in an electrolyte under a voltage. In comparison to classical mechanical and thermal processes, the anodic dissolution of the metal has the advantage that no undesirable surface modifications, such as dislocation formation, occur. The ECM process is independent of mechanical parameters, such as hardness, and is therefore also suitable for materials with a high strength. The reaction mechanisms that occur are not yet known in some cases and lead to complex surface modifications that are difficult to predict. This leads to cost-intensive process and tool design, which is often only possible iteratively and thus limits the use of ECM. This is where our research group wants to start, provide an essential contribution to the understanding of the electrochemical process and enable an optimized and resource-saving application of the ECM technology in the future. To achieve these goals, we must address several aspects. First, we want to understand the responsible chemical reaction mechanisms, such as anodic dissolution and oxide layer formation, as well as the influence of the current density during different process variants. For this purpose, experimental investigations will be carried out both at the laboratory scale and at the scale of the actual ECM process. In addition, a methodology will be developed that allows efficient and accurate simulative prediction of the process in terms of computational time. Our interdisciplinary research group has already successfully collaborated within the SFB TRR 136. Within the framework of the project now applied for, we want to continue our first promising joint work.

• DFG Programme: Research Grants