Presented at the COMSOL Conference 2008 Hannover The Multiphysics Approach: The Electrochemical Machining Process R. van Tijum, T. Pajak Advanced Technology Center November, 2008
Outline Introduction ECM 2
Royal Philips Electronics Founded in 1891 Headquarters: Amsterdam, The Netherlands Globally present with manufacturing sites in 28 countries and sales outlets in 150 countries One of the largest global diversified industrial company with sales in 2007 of EUR 26,793 million A multinational workforce of 133,000 employees (April 2008) An R&D force with expenditures of EUR 1,629 million (2007) 3
A global presence Design, development and assembly centers throughout the world Oral Healthcare Televisions Babycare Televisions Shavers Domestic Appliances Televisions PC Monitors Portable Audio Televisions Home Entertainment Televisions 4
2007 results: Consumer Lifestyle * Focused on innovative lifestyle solutions for personal wellbeing Many leading market positions Contributing to the Philips brand Strong marketing and sales capabilities Consumer-driven insights and dedicated business models driving innovation and differentiation Entering strategic new value spaces Driving sustainable, profitable growth Active Crystals Arcitec Portable Media devices Flexcare Latin America North America Asia Pacific 9% 20% 15% 56% Europe *Results given are based on 2007 results reported by the Consumer Electronics and DAP divisions prior to their merger into the Consumer Lifestyle sector on January 1, 2008 Sales FY2007 Other Home Networks Periph & Access Entertainment solutions 15% 5% 3% 7% Shaving & Beauty 9% 48% 4% 9% Health & Wellness Domestic Appliances Connected Displays 5
Making a difference The Consumer Lifestyle businesses Television Shaving & Beauty Domestic Appliances Audio Video & Multimedia Peripherals & Accessories Health & Wellness 6
ATC, Advanced Technology Center ATC is CL technology center serving all Lines of Business 110 employees (90% PhD, MSc and BSc) Our key success factor is our in-depth understanding of CL applications focussing on domestic appliances Shaving & Beauty Domestic Appliances Oral HealthcareHealth & Wellness 7
Cap Shaving head Trimmer Drive train Handle Motor Indicator Battery
Shaving cap production process More complex shape Coldforming Heat treatment Shorter time to market Process development lead-time Finishing 600 500 time (wks) 400 300 200 100 0 1990 1995 2000 2003 2006 9
Cold forming Finishing (ECM) cathode U Electrolyte flow dissolution Inter Electrode gap anode Before ECM Outer side Inner side Holes and slits sequence Shine 10
Business objectives We are constantly seeking opportunities to: Enhance shaving performance Increase profitability Improve process robustness & predictability Product accuracy Investments and process cost Cost of Non Quality 11
Approach To simulate the ECM process ECM is not a black box process! Process simulation to be used upfront experiment to get process settings much closer to these optimal for given result. Simulation results depends on the model used; it can greatly support and minimize experimental effort but cannot eliminate real-time experiments. 12
5 Desired states Process development time is decreased Development cost is minimized Experiments run mainly virtually (are simulated) Real experiment goes first time right after simulation Simulated process is robust and accuracy fulfills specification requirements 13
Inventory of process governing principles Process disturbances (!) e.g. support misalignment Model ECM Process outputs: Shape Faraday s law driven dissolution Navier-Stokes description of electrolyte flow conditions (also for compressible non-newtonian liquid) in laminar & turbulent domain Deformation Temperature Ohm s Law and distribution of electric field Flow Overpotential Electric field Gas Joule-Lentz heat generated during dissolution increasing electrolyte conductivity Oxygen & hydrogen gas evolution altering flow conditions and decreasing conductivity Process parameters: - Voltage - Electrolyte concentration - Flow pressure - Inter electrode gap -... Input: product shape Overpotential of cathode & anode Current efficiency dependency Possible elastic deformation of the typically fragile (thin wall) product due to electrolyte pressure 14
Multiphysics high level problem description ECM model by balance Mass balance equations for the process gap Energy balance equations 15
ECM modelling map internal / external Philips Model accuracy Desired accuracy Comsol simulations Matlab simulations Functional simulation tool Bubble size = = range of applications External of Philips Developed by Philips CFX simulations Past FEM simulations (SEPRAN) SolidWorks simulations Small matlab Simulations (electric field) C++ programmes Desired simplicity Monograms simplicity 16
Material dissolution Reactions (selection): Me Me n + + n e 2 e + 2 H O H + 2( OH ) 2 2 + H O O + 4H 4e 2 2 2 + Material dissolution: Electrolyte flow cathode dissolution anode Inter Electrode gap v n = K η( J ) J [m/s] Efficiency η(j : ) M I Δm theory = Δt z F Δmexperimental 2 η( J ) = = c1 + ( c2 c1 ) atan( c3( J c4)) [%] Δm π theory where: J K c 1, c 2, c 3, c 4 current density electrochemical constant process constants 17
Conductivity Temperature (T) Joule s heating Conduction Convection Gas concentration (C) Flux at the surface Diffusion Convection Electrolyte flow cathode dissolution anode Inter Electrode gap Conductivity: 1 = ρ (1 + volfrac) bp (1 + α( T σ 0 T ))[m/s] 0 Where the gas volume fraction is: C volfrac = [-] C + M el 18
Multiphysics model validation case Variables: Inlet temperature (10, 25 and 40 o C) Solution concentration (50, 130 and 230 g/l) Outcome: Material removal efficiency to determine: 2 J ) = c + ( c c ) atan( c ( J ))[%] η ( 1 2 1 3 c4 π Experimental setup Experimental results Simulation 19
Experimental setup Schematic of the lab scale process: <0.5mm Sample inflow v Electrode 5 mm outflow T sensor V Experimental setup Experimental results Simulation Experimental setup (top view): 20
Experimental results Material dissolution speed: v n = K η( J ) J [m/s] Efficiency: Δmexperimental 2 η( J ) = = c1 + ( c2 c1 ) atan( c3( J c4))[%] Δm π theory Experimental setup Experimental results Simulation Best fit: c c c c 1 2 3 4 = 40.7 = 75.4 0.0676 T + 1.86 ln( C) = 0.684 0.00772 T 0.0475 ln( C) = 2.05 + 1.25 T + 0.0387 C 0.00437 C T 21
COMSOL multiphysics model Model inflow v <0.5mm Sample Electrode outflow V Experimental setup 5 mm T sensor Experimental results Simulation 22
Comsol multiphysics model: process variables <0.5mm inflow v Sample Electrode 5 mm outflow T sensor V Experimental setup Experimental results Simulation 23
of material removal Comparison of profile measurements and simulations Experimental setup Experimental results Simulation 24
Example: creating a cavity in a shaving cap Simulation: Inflow outflow flow domain Electrode (ground) Shaving cap (potential) Mesh: - Coupled physics (axial symmetric): - Navier-stokes (u,v) - Potential (V) - Convection/diffusion (C) - Convection/conduction (T) - Moving mesh (r,z) -Time: 0 to 10 seconds - Feed rate: 25 um/s 25
Flow velocity [m/s] Temperature [K] Reaction gas fraction [-] Conductivity [m/s] 26
Simulation of material dissolution in practice Philips Arcitec 27
s Progress so far: Development cost is minimized Process development time is decreased Experiments run mainly virtually (are simulated) Real experiment goes first time right after simulation Simulated process is robust and accuracy fulfills specification requirements 28
Acknowledgement We would like to thank: Dr. W. Hoogsteen for his contribution in the experimental research and consultancy P.J. Huizenga MSc for his research work on this subject during his traineeship 29