Elsyca ECMMaster is a unique 3D software tool for electrochemical machining process simulation and optimisation. Elsyca ECMMaster provides the ECM industry an intelligent tool for managing costs, attaining higher productivity, accelerating ecological gains and simultaneously improving customer service & product quality.

Elsyca ECMMaster guides the engineer through the different simulation stages:
 

CAD creation: Elsyca ECMMaster creates (or imports from file) the complete geometrical ECM setup (cathode tool/workpiece) using state-of-the art CAD tools; pre-processing: Elsyca ECMMaster reads the electrolyte bath characteristics from file or database; meshing: Elsyca ECMMaster automatically meshes your ECM setup; boundary conditions: Elsyca ECMMaster enables to impose direct or (bipolar) pulsed currents through multiple electrodes, to set up the feed rate for the moving cathode tools and define the total process time; solving: Elsyca ECMMaster computes the current density and the electrode shape change rates and creates a CAD model of the final workpiece surface; post-processing: Elsyca ECMMaster has powerful visualisation tools within the user CAD environment;

• optimization and reverse engineering: Elsyca ECMMaster enables to rework and optimize the cathode tool geometry using a limited number of iteration steps in order to achieve a predefined workpiece shape.

Elsyca ECMMaster Key Features:

• entirely integrated in SolidWorks® (www.solidworks.com) offering a cost-efficient & user friendly interface for your CAD product designs and ECM reactor configuration;
• file import from numerous CAD packages such as IGES, STEP, SAT (ACIS), VDAFS, DXF, PARASOLID, ProE, Inventor, …
• very fast and highly accurate hybrid grid generator;
• robust and prompt numerical solver, calculating potential, current distribution and electrode shape change rate for complex 3D configurations;
• powerful visualisation tools with optional output to Tecplot® (www.tecplot.com) via the software product ‘Tecplot for ECMMaster’.

Elsyca ECMMaster Solver Key Features:

parameterisation of reactor dimensions (standard SolidWorks® feature); imposed DC or pulsed potential / current signals on different electrodes; imposed current through one or a collection of electrode faces (includes floating electrodes modelling); electrode polarisation & efficiency defined by linear or Butler-Volmer type relations, or through direct data import from file (splines); computation of the new shape of the workpiece in CAD format (watertight model) at discrete stages over the total process time.