電化學加工（Electro chemical machining）是一種以電解原理為基礎的加工技術。加工時工具作為陰極，工件作為陽極，在電解液中陰極和工件之間發生氧化還原反應，造成陽極工件被溶蝕。本研究整理了相關電化學文獻資料，使用數值模擬對其電極加工間隙、模型內熱流場與材料移除進行分析，為往後研究奠定依據基礎。
本研究利用SolidWorks及ANSYS SpaceClaim建立發動機機匣加工模型，使用軟體COMSOL Multiphysics和ANSYS Fluent建立非結構型網格，並設定邊界條件求解後進行後處理分析，最後利用Tecplot及SigmaPlot進行數據彙整與圖表製作。本研究為多重物理耦合，加工過程中耦合熱場、流場、電場與移動網格，模擬實際電化學加工現象，並探討改變參數於加工深度之影響，用於進行實際加工前分析與評估。
研究結果發現，改變入口速度能有效改善電解液的熱堆積。改變加工電壓能增加材料移除效率，但提升電壓也將產生較大之焦耳熱能，若此時流場散熱不佳，將形成工件表面有高低差之現象。粒子追蹤模擬能夠了解加工電解產物之走向，以利流場入出口的設計。
關鍵字：電化學加工、數值模擬、熱流場分析、材料移除率、粒子追蹤

In this paper, it is argued that a 3D coupled multiphysics finite element model is a suitable way to further develop the ability to model the electro chemical machining(ECM) process. In this study, SolidWorks and ANSYS SpaceClaim are used to build the model of aircraft engine case. COMSOL Multiphysics and ANSYS Fluent are used to build the unstructured mesh, and the boundary conditions are set to solve the problem. Finally, Tecplot and SigmaPlot are used for data collection and chart production.
In order to confirm the numerical method and the accuracy of the simulation, we set up four test cases, including aluminum alloy multiphysics heat flow field and material removal simulation, two-dimensional hole machining simulation and particle tracking simulation of microfluidic cell flow in porous media.
This paper presents a new approach for modeling the ECM material removal process by coupling the conservation equations for fluid flow, electric fields, material removal(moving grid), and heat transfer. Based on initially introduced governing equations, possible coupling strategies are presented and discussed, which can be used for analysis and evaluation before actual machining.
Key words: Electrochemical Machining, Finite Element Model, Material Removal Rate, COMSOL Multiphysics, ANSYS Fluent, Particle Tracking.

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