Multiphysics Simulation of ECM for the Machining of Al-SiC Composites

Abstract

Al–Si composite is one of the widely used MMC in various application. It has some specific properties like high thermal conductivity and high strength-to-weight ratio which tend to use it in some high-end applications like microelectronics, aerospace, automobile, etc. In spite of its exceptional properties, Al-SiC is also one of the difficult composites to machine. So, machining of Al-SiC composite with a conventional process would face challenges. Unconventional process like electrochemical machining process offers a better alternative in generating accurate complex geometries in difficult to machine material. By varying the parameters of ECM process, the material removal of Al-SiC can be varied. Further, the material removal from ECM process is also influenced by the composition of Al-SiC. In this paper, multiphysics models have been developed in COMSOL to characterize the electrochemical process to study the material removal of Al-SiC. The parametric study is also performed to study the influence of machining parameters on material removal. This work can provide details on the ECM process for the machining of Al-SiC.