Study of the electrolyte flow at narrow openings during electrochemical machining

Modelling of ECM is a powerful tool to improve the cost- and time intensive tool-development process. However, for certain combinations of process and geometric parameters, the simulation results include non-physical negative pressure values inside the electrolyte flow. These phenomena occur near the narrow opening into the machining gap. According to Bernoulli's law, it is plausible that low-pressure values are present in this region possibly leading to evaporation. Based on these facts, it was hypothesized that cavitation could occur during ECM. In order to successfully validate this hypothesis, the electrolyte flow is analysed both in experimental as well as simulation-based studies.