This work presents a novel approach to efficiently model anodic dissolution in electrochemical machining. Earlier modeling approaches employ a strict space discretization of the anodic surface that is associated with a remeshing procedure at every time step. Besides that, the presented model is formulated by means of effective material parameters. Thereby, it allows to use a constant mesh for the entire simulation and, thus, decreases the computational costs. Based on Faraday’s law of electrolysis, an effective dissolution level is introduced, which describes the ratio of a dissolved volume and its corresponding reference volume. This inner variable allows the modeling of the complex dissolution process without the necessity of computationally expensive remeshing by controlling the effective material parameters. Additionally, full coupling of the thermoelectric problem is considered and its linearization and numerical implementation are presented. The model shows good agreement with analytical and experimental validation examples by yielding realistic results. Furthermore, simulations of a pulsed electrochemical machining process yield a process signature component of the surface roughness related to the specific accumulated electric charge. The numerical examples confirm the simulation’s computational efficiency and accurate modeling qualities.

这项工作提出了一种有效模拟电化学加工中阳极溶解的新方法。早期的建模方法采用阳极表面的严格空间离散化，这与每个时间步的重新网格化程序相关。除此之外，所提出的模型是通过有效的材料参数制定的。因此，它允许在整个模拟中使用恒定网格，从而降低计算成本。根据法拉第电解定律，引入了有效溶解水平，它描述了溶解体积与其对应的参考体积之比。通过控制有效的材料参数，这个内部变量允许对复杂的溶解过程进行建模，而无需进行计算成本高昂的重新网格划分。此外，考虑了热电问题的完全耦合，并提出了其线性化和数值实现。该模型通过产生真实的结果显示出与分析和实验验证示例的良好一致性。此外，脉冲电化学加工过程的模拟产生与特定累积电荷相关的表面粗糙度的过程特征分量。数值例子证实了模拟的计算效率和准确的建模质量。脉冲电化学加工过程的模拟产生与特定累积电荷相关的表面粗糙度的过程特征分量。数值例子证实了模拟的计算效率和准确的建模质量。脉冲电化学加工过程的模拟产生与特定累积电荷相关的表面粗糙度的过程特征分量。数值例子证实了模拟的计算效率和准确的建模质量。