Actual Tasks in Creating Digital Twins for Precise Electrochemical Machining
DOI:
https://doi.org/10.33042/2079-424X.2024.63.1.02Keywords:
Electrochemical Machining, Multi-physics Simulation, Digital Twin, Industry 4.0Abstract
The development and application of manufacturing processes digital twins is an established trend in the development of precision machining methods, which is inherent in Industry 4.0. Digital twins are most actively implemented in additive manufacturing and for non-deformation finishing processes: laser, electrical discharge, and electrochemical. The main advantage of this approach is the ability not only to understand and control the process but also to manage it in real time while simultaneously monitoring the condition of the equipment. Electrochemical machining (ECM) is stands out among non-deformation methods. ECM combines high material removal rates with the absence of tool wear and thermal effects on the processed material. The most promising process is pulsed electrochemical machining (PECM), in which the cathode carries oscillatory motion and high-density electrical pulses are applied when it is near the lower dead center. This ensures high productivity and processing accuracy, as well as improved conditions for electrolyte renewal in the machining zone during the cathode's return stroke. Due to the complexity and interrelated of the processes involved in PECM, multi-physical models are used to create digital twins. Based on the review of existing models for PECM, tasks have been formulated for creating DT of machining processes for complex-shaped details, where two-dimensional models, which most modern research is based on, cannot be applied. The most important tasks are the design of cathodes, optimization of electrolyte supply and integration of electrochemical machining process digital twins and equipment for its implementation. The possibilities of creating such integrated digital twins using available software on the market are determined.
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