Simulation of Production Processes using the Multiphysics Approach: The Electrochemical Machining Process

The electric shaver is one of the successful products of Philips. One of the reasons of the superior shaving performance is the accuracy of the functional part of the shaver made from TRIP steel. The production process of this part consists of cold forming, heat treatment and finishing. The last step assures final product accuracy and thus enables required shaving performance. Electrochemical Machining process (ECM) is used as the finishing technological operation, which additionally enables accurate 3d shape freedom. The aim of this paper is to explain complexity of the interactions involved in the ECM process. This is done experimentally using laboratory set-up - a flow channel cell that resembles production process and by modeling in COMSOL Multiphysics where a validated model is created. The last part of the paper shows how COMSOL simulation is applied to support design of ECM process of the shaving cap.