Interdisciplinary modelling of the electrochemical machining process for engine blades

In this paper an interdisciplinary simulation model of the electrochemical machining (ECM) process for aero engine blades is set up. Simulation results of a compressor vane are presented and compared to optical measurements of actual manufactured workpieces. The simulation model is based on conservation equations for the electric field, fluid flow and heat transfer in combination with analytical functions for the influence of temperature and gas evolution on the specific electrical conductivity. Validation is done by optical in situ measurements. Finally construction rules for an inverse modelling approach are examined and simulation results of the calculated cathode geometry are presented.