COMSOL modelling of Wire Electrochemical machining for cutting steel sheets

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I have created a 2D geometry for COMSOL simulation modeling, and I have attached the relevant files for reference. The geometry consists of two squares:

The upper square represents the electrolyte flow domain, with its inlet and outlet indicated in the attached files. The lower square represents the workpiece. Additionally, a circle within the upper square represents the wire. I need assistance with the following aspects:

I have resolved multiple errors encountered during the simulation; however, I am struggling with one final error: "Inverted Mesh Element." Despite my efforts, I have been unable to fix it.

In the simulation, I require tool movement towards the workpiece. I have attempted various solutions, but the tool movement is not occurring as expected.

Furthermore, I would appreciate feedback on whether the selected physics in the simulation are correct. If any modifications are necessary, please provide guidance. I am completely stuck on this issue and have been struggling with it for the past 20 days without success.

I request all viewers to kindly assist me in resolving these problems. I have attached screenshots of the error encountered & physics invoved in the COMSOL simulation file. A reference research paper for better understanding is "Modelling of Wire Electrochemical Micromachining (Wire-ECMM) process for anode shape prediction using finite element method" by Vyom Sharma, Ishan Srivastava, V.K. Jain, J. Ramkumar.



1 Reply Last Post 2025年3月19日 GMT-4 09:07
Jeff Hiller COMSOL Employee

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Posted: 1 week ago 2025年3月19日 GMT-4 09:07
Updated: 1 week ago 2025年3月19日 GMT-4 10:33

Hello Prashant,

You will find recommendations on how to make a moving mesh more resistant to element inversion in this blog post and this second blog post.

If the difficulty persists, please upload your .mph file. There's only so much that can be guessed about how you set up the model from screenshots.

Best regards,

Jeff

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Jeff Hiller
Hello Prashant, You will find recommendations on how to make a moving mesh more resistant to element inversion in [this blog post](https://www.comsol.com/blogs/model-translational-motion-with-the-deformed-mesh-interfaces) and [this second blog post](https://www.comsol.com/blogs/deformed-mesh-interfaces-rotations-and-linear-translations). If the difficulty persists, please upload your .mph file. There's only so much that can be guessed about how you set up the model from screenshots. Best regards, Jeff

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