Engineers who work with AltaSim Technologies bring products to market faster, at lower cost, and with more optimized designs by leveraging our expertise in multiphysics simulation. This case study highlights how our team helped a client streamline complex post-processing workflows and expand simulation access across their engineering team.
Problem:
The client's engineering team was developing COMSOL Multiphysics® models to simulate material removal during electrochemical machining (ECM). Their initial approach incorporated Primary Current Distribution and a Moving Mesh to reflect the changing workpiece geometry. However, simulation convergence proved challenging due to numerical instability in interface currents and persistent mesh failures as cathode tools approached the workpiece. As a result, the team sought a reliable and reproducible methodology that would (1) consistently converge under realistic operational scenarios, and (2) reveal design-space sensitivities without extensive trial-and-error over an extended period.
Solution:
AltaSim collaborated closely with the client to enhance their simulation methodology for electrochemical machining. Through a revised modeling strategy and refined simulation setup, the team systematically addressed fundamental challenges hindering successful results. Best practices were applied to manage complex, moving-boundary problems, ensuring that the simulation process delivered robust and reliable outcomes. Comprehensive documentation and training were also provided, equipping the client's engineers with the skills necessary to confidently utilize and adapt the enhanced methodology for current and future projects.
Results:
As a result of these improvements, the client achieved stable and physically accurate current density fields at the machining interface, effectively eliminating the noise and instability previously observed in their simulations. Time-dependent analyses operated reliably, even when cathode tools approached minimal gap distances, owing to the optimized remeshing strategy and mesh controls.
Consequently, the client was able to establish practical operational boundaries for tool advance rates and corner geometries, facilitating robust process planning and comprehensive design-space exploration. The provided model, comprehensive documentation, and training enabled the client's team to independently execute, diagnose, and further develop the simulation methodology for both ongoing and future initiatives.
What We Delivered:
AltaSim delivered a robust and dependable ECM simulation model in COMSOL Multiphysics®, accompanied by thorough documentation detailing the solver, mesh, and physics configurations.
Additionally, we prepared a comprehensive presentation summarizing key modifications and recommended best practices, facilitating ease of understanding and implementation for engineers. To promote effective adoption, we conducted targeted training sessions that equipped the customer’s team with the expertise required to independently operate, troubleshoot, and customize the methodology for future projects.
AltaSim partners with companies to provide simulations that increase the knowledge and understanding of our clients’ engineering staff. We work collaboratively with our clients through these simulations to develop actionable plans to solve their engineering challenges.
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