• Avinash M. Pawar

Electrochemical Drilling Process (ECD) provides the alternative to traditional or conventional drilling processes without a direct contact between the tool and the workpiece, with high material removal rates, irrespective of diverse mechanical properties of the workpiece. Even though ECD has a great potential, the process is still not fully explored and its research is in process. ECD involves number of phenomena such as electrochemistry, mass transfer, heat transfer and hydrodynamics. Due to this it is very difficult to predict the hole diameter accurately in ECD. This problem is considered for investigation by developing a Multiphysics simulation model for ECD and the effect of tool geometry on generated anode profile is studied to improve the dimensional control and performance of the Electrochemical Machining Process. For development of Multiphysics simulation model for the tool design in ECM hole making process, finite element analysis (FEA) software, COMSOL is used because of its capability to couple various phenomena in ECM process in a single model for better accuracy. The performance characteristics namely; overcut and height of spike generated is predicted by simulation and validated with the experimental results for the accuracy and capability. The predicted and experimental results agreed well and the developed innovative simulation model provides complete visualization and understanding of the ECD process.

Electrochemical Drilling, ECD Multiphysics simulation, current density distribution, metal removal rate, dimensional accuracy

"MULTIPHYSICS SIMULATION AND EXPERIMENTAL VALIDATION OF ECM DRILLING PROCESS", International Journal of Emerging Technologies and Innovative Research (www.jetir.org), ISSN:2349-5162, Vol.6, Issue 1, page no.682-689, January-2019, Available :http://www.jetir.org/papers/JETIR1901291.pdf

"MULTIPHYSICS SIMULATION AND EXPERIMENTAL VALIDATION OF ECM DRILLING PROCESS", International Journal of Emerging Technologies and Innovative Research (www.jetir.org | UGC and issn Approved), ISSN:2349-5162, Vol.6, Issue 1, page no. pp682-689, January-2019, Available at : http://www.jetir.org/papers/JETIR1901291.pdf