In contrast to conventional techniques, electrochemical machining (ECM) allows the wear-free machining of high-strength materials. The subsurface areas of the workpiece are furthermore not subjected to any mechanical or thermal stress, and the pulsed electrochemical machining is capable of achieving particularly high levels of geometric complexity and surface quality.
Conventionally, tool design operations are performed manually and require several iterations. Modern tool design strategies, conversely, are often simulation-assisted. Reliable data-based predictions of the electrochemical machining have already paved the way towards new applications of the technology – specifically in aero engine manufacturing, medical technology and tool and die manufacturing.
The Fraunhofer IPT is conducting fundamental research into the removal behaviour of various steel and titanium materials as well as nickel-based alloys under different electrolysis systems and process energy parameters. This allows the application-specific design and engineering of industrial processes. We are already using simulation-assisted tool design strategies and are continuously optimizing these strategies on the basis of newly acquired skills and experiences.
- Simulation-assisted cathode design
- Technology development for DC-ECM and P-ECM
- Fundamental research into material removal behaviour