Electrochemical machining (ECM) is a machining process that can change the surface of any conductive material, no matter its properties. This flexibility has made ECM popular for improving surface designs. However achieving the ideal surface finish is complicated and often relies on trial and error, which is costly and time-consuming. Therefore, there was a need for a multiphysics model to accurately calculate the right amount of material removed. Multiphysics modelling involves the analysis of multiple simultaneous physical factors to simulate real-world conditions and predict performance more accurately.
A large automotive company wanted to improve fuel efficiency in engines and hydrogen fuel systems. They approached Holtex to take advantage of ECM to improve internal geometries in aluminum parts, which required complex modelling beyond Holtex’s current capabilities. Holtex is a problem-solving engineering company based in West Yorkshire, committed to supporting the maintenance and service of machinery and equipment.
The project – a collaboration between Holtex and the University of Huddersfield – used computational fluid dynamics to create a multiphysics model of the ECM process. The goal was to test the model’s accuracy and find general trends for setting up the ECM process. The University of Huddersfield ran digital simulations to optimise the ECM process. This allowed Holtex to adjust its test settings, which were then used in real-world applications at the customer’s site.
AMPI provided crucial support for this project through its I4M funding programme, which facilitated rapid deployment of academic resources and enabled a smooth integration of academic expertise and practical application. This collaboration enabled Holtex to access advanced software and expertise they lacked internally. This resulted in a significant reduction in development time and costs – instead of spending six to nine months recruiting specialised skills and acquiring necessary software, Holtex could focus on immediate application and testing.
The development and optimisation of the multiphysics model for ECM presents substantial opportunities for time and cost savings. Once fully optimised, the model will serve as a digital twin, replacing the need for continuous experimental trials. This advancement will allow for precise assessment of changes in reaction rates and anodic dissolution, enhancing the efficiency and accuracy of the ECM process. Future collaborations with AMPI and its academic network could further refine and expand the capabilities of the ECM process.
“This project allowed rapid deployment of academic support without many hurdles. The six-figure revenue has been realised – with more to come – and it’s helped bolster follow-on commitment. Good value for money.”
Aaron Holt, CEO, Holtex.
