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Modeling and Numerical Analysis of Advanced Machining for Orthotic Components
Abstract
Electrochemical micromachining plays a vital role in the advanced machining domain. Particularly, it helps the medical industry in machining micro-level devices in hardened materials. Though it is maintaining a very small inter-electrode gap during machining, it is required to understand suitable machining parameters before machining. These parameters can be achieved by proper modeling and simulation. In this chapter, a model for flow analysis of electrolytes in inter-electrode gaps is designed to obtain optimal process parameters for machining. The geometric model used in this simulation consists of cylindrical workpiece, an inlet allowing the flow of sodium nitrate solution as electrolyte to the machining zone, and a cylindrical tool with a flat end. Electrolytic flow simulation is incorporated using computational fluid dynamics by ANSYS–CFX 15.0 for finding pressure variation, streamline velocity pattern, turbulent energy, and temperature contour in IEG. According to the CFD analysis, the passivation effect, stagnation effect, pressure, and temperature zone are studied.
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