Simulation-Based Development of ECM Processes
ECM Group


Cathode Design
In industry, tools for ECM are designed by heuristic procedures that require multiple cost and time-consuming iterations. The developed multi-physic simulation model predicts the resulting workpiece geometry for a given cathode and thereby shortens the design process.

Process Design
The simulation calculates the velocity and temperature field as well as the gas evolution in the electrolyte. Consequently, generator and flushing parameters can be chosen in such a manner that regions of recirculation and evaporating electrolyte are prevented.

Experimental Basis
Modelling of the ECM processes is carried out in strong collaboration with experimental investigations. First, the removal characteristic of the machined materials, which is required as an input to the simulation, is identified in standardized tests. Second, the developed simulation models are validated by means of velocity and temperature measurements as well as machined workpiece contours.

Comparison of the resulting workpiece contour in simulation and experiment:

Simulated electrolyte conditions at the trailing edge of a turbine blade:


Do you have any questions?

Your contact:
Dr.-Ing. Andreas Klink
Chief Engineer
Cluster Produktionstechnik 3A 438
Tel.: +49 241 80-28242
Fax: +49 241 80-22293


Lukas Heidemanns, M.Sc. RWTH
Workgroup Leader
Cluster Produktionstechnik 3A 234
Tel.: +49 241 80-28007
Fax: +49 241 80-22293