Component manufacture by means of electrochemical removal
The method improves electrochemical machining by simulating electrochemical ablation with adaptive discretization and multiphase flow modeling, addressing inefficiencies in manufacturing complex components like gas turbine blades, enhancing accuracy and speed.
Patent Information
- Application Number
- PCT/DE2025/100752
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-08-12
- Filing Date
- 2025-08-07
- Publication Date
- 2026-02-19
AI Technical Summary
Existing electrochemical machining methods struggle with inefficiencies in simulating and optimizing the manufacturing of complex components, particularly for materials like nickel superalloys, due to challenges in accurately modeling electrochemical erosion and material removal processes.
A method and system for simulating electrochemical ablation that includes calculating electrochemical erosion based on input parameters, adapting spatial discretization, considering multiphase flows and heat transfer, and validating against actual manufacturing data to improve simulation accuracy and speed.
Enhances the simulation and manufacturing process of complex components by allowing more accurate, faster, and less resource-intensive simulations, enabling better design and monitoring of electrochemical machining processes.
Smart Images
Figure DE2025100752_19022026_PF_FP_ABST
Abstract
Description
[0001] Component manufacturing using electrochemical machining
[0002] The present invention relates to a method for manufacturing a component by means of electrochemical ablation, a method for manufacturing a cathode for this manufacturing of a component, a method for designing the manufacturing of the component, a method for simulating the manufacturing of the component, and a system or computer program or computer program product for carrying out a method described herein.
[0003] Electrochemical machining (ECM) is a subtractive manufacturing process particularly suitable for very hard materials, such as nickel superalloys. ECM processes can advantageously produce highly complex three-dimensional shapes, especially gas turbine rotors and / or guide vanes. In electrochemical machining, the component or workpiece to be manufactured is polarized as the anode (positively charged), and the tool (electrode) as the cathode (negatively charged). A sink gap is formed between the anode and cathode, containing an electrolyte. This electrolyte dissolves the material to be removed from the component or workpiece by means of a voltage applied to the anode and cathode. Electrochemical machining can be performed continuously or in pulsed / precise electrochemical machining (PECM). In both cases, the electrode determines the shape of the component or workpiece.
[0004] One objective of an embodiment of the present invention is to improve component manufacturing by means of electrochemical material removal.
[0005] This problem is solved in particular by a method with the features of claims 12 and 13. Claim 10 protects a method for designing the manufacturing process of the component, claim 1 a method for simulating the manufacturing process, which can be used particularly advantageously for designing the manufacturing process and manufacturing the component and / or the cathode (for this purpose), and claims 14 and 15 a system or computer program or computer program product for carrying out a method described herein. The subject matter of these claims can also improve component manufacturing by means of electrochemical machining. The dependent claims relate to advantageous embodiments.
[0006] According to one aspect of the present invention, a preferably computer-implemented method for simulating the manufacturing of a component by means of electrochemical ablation comprises the following step, which in one embodiment is at least partially automated:
[0007] - Providing input parameters.
[0008] The component comprises, in one embodiment, one or more blades, in a further development, guide vane and / or rotor blade(s), and / or a blade carrier of a gas turbine, which in a further development is integrally formed with the blade(s) or manufactured bladeless. It can, in particular, consist of the blade(s) and / or the blade carrier. Manufacturing a bladeless blade carrier can, in particular, include producing one or more grooves for the subsequent attachment of blades. A blade carrier integrally formed with one or more blade(s) can, in particular, include a so-called blisk. In one embodiment, the manufacturing process involves manufacturing, in a further development of the component and / or the groove(s) and / or blisk, from a solid block, in a further development from a single block, and / or without prior roughing or machining.Pre-contouring by means of primary forming and / or (other) material removal, and / or the production of a final or fine contour, in a further development of the component and / or the groove(s) and / or blisk. The present invention is particularly advantageous for the production of such components due to the materials, geometries and boundary conditions commonly used there.
[0009] The provided input parameters can preferably be a cathode voltage (for manufacturing by electrochemical machining), as defined in a further development; and / or a static inlet pressure of an electrolyte (for manufacturing by electrochemical machining), as defined in a further development; and / or a cathode and / or an anode geometry (for manufacturing by electrochemical machining); and / or
[0010] - at least one material (for manufacturing by electrochemical removal), in particular an electrolyte composition; and / or
[0011] - at least one material property (for manufacturing by electrochemical machining), in a further development a thermal conductivity, preferably of a cathode and / or anode and / or of the component and / or electrolyte; and / or
[0012] - at least one environmental condition, in a further development a temperature, preferably of a cathode and / or anode and / or of the component and / or electrolyte; exhibit, in a further development.
[0013] According to one embodiment of the present invention, the method comprises the following steps, preferably repeated once or, more preferably, multiple times and / or at least partially automated:
[0014] - Calculating electrochemical erosion based on the provided input parameters; and
[0015] - Calculating a component geometry based on this electrochemical removal.
[0016] By calculating the electrochemical removal and the resulting component geometry, preferably in multiple steps, and then preferably again, preferably based on this, a further electrochemical removal etc., the simulation can be improved, in particular (also) on smaller or less powerful computers and / or with less memory and / or can be carried out faster and / or more accurately.
[0017] In one embodiment, calculating a component geometry comprises, in one embodiment at least partially automated, the adaptation of a spatial discretization, in a further development of at least one grid, preferably at least one finite element or FEM and / or at least one finite difference or FDM and / or at least one finite volume or FVM grid, of a numerical model, in particular of the component to be manufactured and / or the cathode and / or the electrolyte, in a further development depending on a quality criterion for the discretization, preferably configurable. This is based on the understanding that through the, preferably repeated, sequence of calculating the electrochemical ablation and the component geometry, a spatial discretization or (volume) elements of a numerical model can become increasingly distorted.The underlying idea is that, preferably from a certain quality criterion, for example, when the discretization becomes (significantly) distorted due to cathode motion and / or material removal, the spatial discretization can be adapted and regenerated in a further development. This advantageously ensures numerically more convergent and / or accurate solutions, thereby improving the simulation, especially allowing it to be performed on smaller or less powerful computers and / or with less memory and / or faster and / or more accurately, and is particularly advantageous in cases of large material removal.
[0018] In one implementation, the calculation of electrochemical erosion includes, at least partially in this implementation, the calculation of a transient, time-dependent, or time-varying three-dimensional erosion resulting from electrochemical reactions. This advantageously improves the simulation, particularly allowing it to be performed on smaller or less powerful computers and / or with limited memory, and / or faster and / or more accurately, thus increasing the speed and / or accuracy of the simulation.
[0019] In one implementation, the calculation of electrochemical erosion is performed based on the temporal and / or local variability of an electrolyte's electrical conductivity, or alternatively, the calculation of electrochemical erosion takes into account the temporal and / or local variability of the electrolyte's electrical conductivity. The electrical conductivity can, in particular, include the ionic and / or electrolytic conductivity of the electrolyte solution. This can advantageously improve the simulation, especially its accuracy, convergence, and / or speed.
[0020] In one embodiment, the calculation of an electrochemical erosion based on a temporal and / or local variability of an electrolyte's electrical conductivity comprises, in a further development, a continuous and / or at least partially automated calculation of a multiphase flow, wherein preferably the Navier-Stokes equations are solved for this or two or more of the phases.In a further development, this calculation of a multiphase flow takes into account one or more of the following influences: a flow of the liquid electrolyte, in an embodiment specifying the locations where liquid electrolyte flows; and / or insulation by air, in an embodiment specifying the areas insulated by air; and / or a production of reaction gas, preferably gaseous hydrogen, in an embodiment specifying the locations where a reaction gas, preferably gaseous hydrogen, is produced; and / or an evaporation, in particular a cavitation, of the electrolyte due to heat and / or static pressure, in an embodiment specifying the locations where electrolyte evaporates due to (strong) heat generation and / or where electrolyte evaporates due to (low) static pressures, in particular where cavitation occurs (due to (strong) heat generation and / or (low) static pressures).
[0021] In one embodiment, the calculation of an electrochemical, in one embodiment at least partially automated, removal process, in one embodiment transient and / or three-dimensional, particularly based on the provided input parameters, and / or the calculation of a component geometry, in one embodiment spatial or three-dimensional, in one embodiment at least partially automated, particularly based on this electrochemical removal process, in a further development, the calculation of an electrochemical removal process based on a temporal and / or local variability of an electrical conductivity of an electrolyte, in one embodiment continuous, calculation of a multiphase flow, in one embodiment three-dimensional, wherein this multiphase flow comprises, in addition to liquid electrolyte, gaseous electrolyte and / or, in particular, gaseous air, and in a further development also includes, in particular, gaseous hydrogen.
[0022] It has surprisingly turned out that by taking these influences into account when calculating a multiphase flow, the simulation, in particular accuracy, convergence and / or velocity, can be significantly improved.
[0023] In one embodiment, the calculation of electrochemical erosion includes taking into account heat transfer via a multiphase flow; and / or heat conduction of the component and / or heat conduction of at least one cathode, preferably insulation of the cathode, for example plastic insulation and / or on a (component-facing) cathode back side to avoid unwanted erosion at other locations; and / or a temperature field of a fluid, preferably the electrolyte, and / or a temperature field of the component and / or a temperature field of at least one cathode; wherein taking into account one or more of these factors in an embodiment may include, preferably, a coupled calculation of the factor(s), in particular,
[0024] This calculation allows phase transformations, particularly of vaporized electrolyte, and the resulting changes in the electrolyte's electrical conductivity (due to both temperature and phase transformations) to be determined and considered with exceptional accuracy, speed, and / or simplicity. These changes significantly impact material removal. Consequently, the simulation, and in particular its accuracy, convergence, and / or speed, can be substantially improved.
[0025] In one embodiment, the temperature field(s), preferably the temperature field of the component and / or the temperature field of at least one cathode and / or, particularly preferably, the temperature field of a fluid, preferably the electrolyte, is coupled with the electrical conductivity of the electrolyte, preferably in such a way that these quantities interact indirectly and / or directly with each other and influence one another. Accordingly, this can advantageously improve the simulation, in particular its accuracy, convergence, and / or speed.
[0026] In one implementation, the procedure comprises the following steps, which in one implementation are at least partially automated:
[0027] - Providing validation data based on the actual manufacturing of one or more components, in particular comprising (each) at least one blade and / or a blade carrier of a gas turbine, by means of electrochemical ablation, preferably based on measurements (during) this actual manufacturing;
[0028] - Providing simulation data, in a further training course temperature data and / or electrolyte mass flow data and / or current data and / or geometry data, based on the calculation of an electrochemical removal and / or a component geometry of a method described here for simulating the manufacturing of the component(s);
[0029] - Comparing the validation data with the simulation data; and
[0030] - Validating and / or adapting the simulation based on this comparison, preferably adapting the simulation in such a way as to reduce the deviation of the simulation data from the validation data, and / or validating the simulation in such a way that it is rated better or well with a smaller or sufficiently small deviation of the simulation data from the validation data. This is based in particular on the idea of comparing the calculated component geometry with (a) actually manufactured component geometry(ies) to validate and / or adapt the simulation, and / or comparing process parameters that occur during real manufacturing, for example, temperatures, electrolyte mass flows, and / or current intensities, with simulated process parameters or process parameters that are calculated or simulated for the simulated manufacturing process. This enables a particularly good multiphysics calibration.Accordingly, this can advantageously (further) improve the simulation, in particular accuracy, convergence and / or speed.
[0031] According to one embodiment of the present invention, a preferably computer-implemented method for designing, and in a further development for parameterizing, the manufacturing of a component with a target geometry by means of electrochemical ablation comprises the following steps, which in one embodiment are at least partially automated:
[0032] - Determining input parameters;
[0033] Simulating the manufacturing process using a method described herein, in particular by providing these input parameters; and
[0034] - Comparing the calculated component geometry with the target geometry, whereby the aforementioned steps (determining input parameters, simulating the manufacturing process, and comparing the calculated component geometry with the target geometry) are repeated while varying the input parameters until a termination condition is met, a predetermined number of simulation runs is reached in a further development phase, or a deviation between the calculated component geometry and the target geometry is smaller than a predetermined limit value, or a predetermined process specification, such as a process duration, machine capacity or utilization, or the like, is met; and
[0035] - Design of the manufacturing process based on the input parameters, preferably those last determined or used, and / or calculated values during the simulation, preferably those last performed, preferably by using these values or values calculated from them, for example taking into account tolerance values, filters or the like, as design parameters, preferably control variables.
[0036] In a training course, one or more of the following input parameters are varied: cathode geometry, electrical voltage, insulation, feed rate, electrolyte mass flow, and / or the positioning of geometries involved in the process, particularly the cathode and / or the component to be manufactured. In this way, the manufacturing process—specifically the cathode and / or the manufacturing process itself, and especially the control and process parameters—can be virtually designed and optimized, thereby improving component manufacturing using electrochemical machining.
[0037] According to one embodiment of the present invention, a method for manufacturing a component comprises the following steps, which in one embodiment are at least partially automated:
[0038] Design of a production facility according to a method described here; and
[0039] - Manufacturing the component using the (such) designed, preferably parameterized, manufacturing process.
[0040] Additionally or alternatively, according to one embodiment of the present invention, a method for manufacturing a component comprises the following steps, which in one embodiment are at least partially automated:
[0041] Simulate, design in a further training course, a manufacturing of the component according to a procedure described here;
[0042] - Manufacturing the component, wherein this manufacturing can be the aforementioned manufacturing of the component by means of the (according to the invention) designed, preferably parameterized, manufacturing process; and
[0043] - Monitoring this manufacturing process, whereby metrologically determined process parameters of this production are compared with process parameters determined through simulation during the design phase. The underlying idea is to compare process variables that occur during actual production, such as temperatures, electrolyte mass flows, and / or current intensities, with simulated process variables or process variables calculated or simulated for the simulated production process during the design phase. This enables particularly effective, especially more precise, sensitive, and / or faster-responding monitoring. Advantageously, deviations of the actual manufacturing process from the theoretical specifications of the simulated or designed manufacturing process can be detected earlier and corrective action can be taken.In one implementation, monitoring involves triggering a reaction; in a more advanced version, it involves intervening in the process and / or issuing a warning. Accordingly, this can advantageously improve manufacturing.
[0044] In addition to or as an alternative to manufacturing the component, the simulation described here can also be particularly advantageous for designing or manufacturing a cathode (intended for or used in the manufacturing of the component). Accordingly, a (method for) designing a manufacturing process for a component can, in particular, include a (method for) designing, especially parameterizing, control parameters, such as feed rates, voltages, electrolyte mass flows or pressures, or the like, for controlling a (corresponding) manufacturing process (for manufacturing the component); and / or a (method for) designing, especially parameterizing, a cathode, in particular a cathode geometry, a material, insulation, or the like (for manufacturing the component).
[0045] Accordingly, according to one embodiment of the present invention, a method for manufacturing a cathode, in particular for manufacturing a component, in particular comprising at least one blade and / or a blade carrier of a gas turbine, comprises the following steps, which in one embodiment are at least partially automated: - Designing, in a further development parameterizing, a cathode, in particular a cathode geometry and / or a material and / or an insulation, according to a method described herein, in particular according to a method described herein for designing a manufacturing process of a component; and
[0046] - Manufacturing a cathode based on the (such) designed, preferably parameterized, cathode.
[0047] According to one embodiment of the present invention, a system, in particular in terms of hardware and / or software, in particular in terms of programming, is set up and / or has the following features for carrying out a method described herein:
[0048] - Means of providing input parameters; and
[0049] - Means for, especially repeated,
[0050] - Calculating electrochemical erosion based on the provided input parameters; and
[0051] - Calculating a component geometry based on this electrochemical removal.
[0052] In one version, the system or its means exhibit:
[0053] Means for adapting a spatial discretization of a numerical model, in particular depending on a quality criterion for the discretization; and / or
[0054] - Means for calculating transient and three-dimensional erosion due to electrochemical reactions; and / or
[0055] Means for calculating electrochemical erosion based on temporal and / or local variability of an electrolyte's electrical conductivity; and / or
[0056] Means for calculating, in particular continuously, a multiphase flow, wherein this calculation of a multiphase flow takes into account one or more of the following influences: a flow of the liquid electrolyte; and / or isolation by air; and / or a production of reaction gas; and / or evaporation, in particular cavitation, of the electrolyte due to heat and / or static pressure; and / or
[0057] - Means for calculating heat transfer via a multiphase flow and / or for calculating the thermal conductivity of the component and / or the thermal conductivity of at least one cathode and / or for calculating the temperature field of a fluid and / or the temperature field of the component and / or the temperature field of at least one cathode; and / or
[0058] - Means for providing validation data based on the actual manufacturing of at least one component, in particular comprising at least one blade and / or a blade carrier of a gas turbine, by means of electrochemical machining; and / or
[0059] - Means of providing simulation data, in particular temperature data and / or electrolyte mass flow data and / or current data and / or geometry data, based on the calculation of electrochemical erosion and / or component geometry; and / or
[0060] - Means of comparing the validation data with the simulation data; and / or
[0061] - Means to validate and / or adjust the simulation based on this comparison; and / or
[0062] Means for determining input parameters and simulating manufacturing and comparing the calculated component geometry with the target geometry, wherein this determination, simulation and comparison is repeated by varying the input parameters until a termination condition is met, in particular a predetermined number of simulation runs is reached or a deviation between the calculated component geometry and the target geometry is less than a predetermined limit value or at least a predetermined process requirement is met, and for designing the manufacturing process based on the input parameters and / or values calculated during simulation; and / or
[0063] - Means for manufacturing a component using a manufacturing process designed as described herein; and / or - Means for monitoring a manufacturing process described herein, wherein metrologically determined process parameters of this manufacturing process and process parameters determined by simulation, in particular design, as described herein are compared with each other; and / or
[0064] Means for laying a cathode according to a method described herein; and / or
[0065] - Means for manufacturing a cathode based on the laid-out cathode.
[0066] A system and / or means according to the present invention can be configured as hardware and / or software, in particular comprising at least one processing unit, preferably connected to a storage and / or bus system via data or signals, and in particular a digital processing unit, especially a microprocessor unit, and in particular at least one CPU, and / or one or more programs or program modules. The processing unit can be configured to execute instructions implemented as a program stored in a storage system, to acquire input signals from a data bus, and / or to output signals to a data bus. A storage system can comprise one or more, in particular different, storage media, in particular optical, magnetic, solid-state, and / or other non-volatile media. The program can be configured to embody the methods described herein.is capable of executing such processes, enabling the processing unit to perform the steps of such procedures and thus, in particular, to simulate or design the manufacturing of a component, or to control or monitor the manufacturing of a component and / or a cathode. A computer program product may, in one embodiment, include a storage medium, in particular a computer-readable and / or non-volatile medium, for storing a program or instructions, or with a program or instructions stored thereon. In one embodiment, the execution of this program or these instructions by a system or a controller, in particular a computer or an arrangement of several computers, causes the system or the controller, in particular the computer(s), to execute a procedure described herein or one or more of its steps, or the program or instructions are configured for this purpose.
[0067] In one embodiment, one or more, in particular all, steps of the procedure are fully or partially computer-implemented, or one or more, in particular all, steps of the procedure are fully or partially automated, in particular by the system or its means.
[0068] Further advantageous embodiments of the present invention will become apparent from the dependent claims and the following description of preferred embodiments. The following is shown, in part schematically:
[0069] Fig. 1 shows a system according to one embodiment of the present invention; and
[0070] Fig. 2 shows a method according to one embodiment of the present invention.
[0071] Fig. 1 shows a system according to one embodiment of the present invention.
[0072] The production of a component comprising at least one blade 8.1 and / or a blade carrier 8 of a gas turbine is illustrated by means of electrochemical machining. For this purpose, an electrical voltage is applied to a cathode 4, which can be moved by an actuator 5, and to the component by means of a power supply 7. Electrolyte is pumped into and out of a sinking gap by means of a pumping device 6. A (P)ECM control 2 is signal-connected to the actuator 5, the power supply 7, the pumping device 6, and a temperature measuring device 3, and controls and monitors the production process.
[0073] Fig. 2 shows a method according to an embodiment of the present invention, which is carried out using a computer 1 on which, in particular, the simulations described below are performed. In step S10, input parameters are provided; in step S20, an electrochemical removal is calculated based on the provided input parameters; and in step S30, a component geometry is calculated based on this electrochemical removal. As long as the simulated manufacturing process is not yet complete (S40: "N"), it is checked whether a spatial discretization of a numerical model used for this calculation still meets a quality criterion. If this is the case (S50: "Y"), the next time step of the simulation is carried out. Otherwise (S50: "N"), the spatial discretization is adjusted, for example, the geometries are remeshed if an FEM mesh is too distorted (Fig. 2: step S60).
[0074] Once the simulation has been performed or the simulated manufacturing process is complete (S40: "Y"), the calculated simulation data is compared with corresponding validation data from a real manufacturing process, and the model is adjusted (step S75) if a deviation in the data is too large (S70: "Y"). If, however, the deviation is not too large (S70: "N"), the simulation, validated in this way, can be used to design the manufacturing process for a component.
[0075] Analogous to steps S10-S70 described above, initial input parameter values are first determined or provided (step S10'). Then, as described above, an electrochemical material removal is calculated based on the provided input parameters (step S20'). Based on this electrochemical material removal, a component geometry is calculated (step S30'). If the simulated manufacturing process is not yet complete (S40': "N"), it is checked whether a spatial discretization of a numerical model used for this calculation still meets a quality criterion (step S50'). If necessary, the spatial discretization is adjusted (step S60'), and these steps S20'-S60' are repeated until the simulated manufacturing process is complete (S40': "Y"). Finally, in step S80, the component geometry calculated in this simulation is compared with a target geometry of the component.If a termination condition is met, for example, a predetermined number of simulation runs has been reached or a deviation between the calculated component geometry and the target geometry is smaller than a predetermined limit value or predefined process specifications are met (S80: “Y”), the input parameters used in this simulation and / or the control or process parameters used or calculated in this simulation are used to design the manufacturing process, in particular a cathode geometry, an electrical voltage, a feed rate, an electrolyte mass flow rate and / or a positioning of geometries involved in the process, then (if applicable) the cathode designed in this way is manufactured (step S90) and, (if applicable) the component is manufactured with this cathode (if applicable using the control parameters) (step S100).This manufacturing process is monitored (in step S100) by comparing the process parameters calculated during the simulation with the process parameters determined by measurement.
[0076] Above, a simulation of a manufacturing process according to an embodiment of the present invention was first validated or adapted (S10-S75) and subsequently used to design and manufacture a cathode (S90) and the component (S100), wherein partial step sequences of Fig. 2 also constitute a method according to an embodiment of the present invention, purely by way of example the steps S10-S60 and S10'-S60' (each) a (method for) simulating the manufacturing of a component.
[0077] In the present disclosure, "has an X" does not generally imply an exhaustive list, but is a shorthand for "has at least one X" and also includes "has two or more X" as well as "has Y in addition to X". Although exemplary embodiments were explained in the preceding description, it should be noted that a multitude of variations are possible. Furthermore, it should be noted that the exemplary embodiments are merely examples and are not intended to limit the scope of protection, applications, or structure in any way.Rather, the preceding description provides the skilled person with a guide for implementing at least one exemplary embodiment, whereby various modifications, particularly with regard to the function and arrangement of the described components, can be made without leaving the scope of protection as defined by the claims and these equivalent combinations of features.
[0078] Reference symbol list Computer (P)ECM control Temperature measuring device Cathode Actuator Pump device Power supply Blade carrier Blade
Claims
Patent claims 1. Method for simulating the manufacturing of a component, in particular comprising at least one blade (8.1) and / or a blade carrier (8) of a gas turbine, by means of electrochemical machining, wherein the method comprises the step: - Providing input parameters (S10; S10'); and exhibiting the, in particular repeated, sequence of steps: - Calculate (S20; S20') an electrochemical erosion based on the provided input parameters; and - Calculate (S30; S30') a component geometry based on this electrochemical removal.
2. Method according to claim 1, wherein the calculation of a component geometry comprises an adaptation (S60; S60') of a spatial discretization of a numerical model, in particular depending on a quality criterion for the discretization.
3. Method according to one of the preceding claims, wherein the calculation of an electrochemical removal comprises a calculation of a transient and three-dimensional removal due to electrochemical reactions.
4. Method according to one of the preceding claims, wherein the calculation of an electrochemical erosion is carried out on the basis of a temporal and / or local variability of an electrical conductivity of an electrolyte.
5. A method according to the preceding claim, wherein performing the calculation of an electrochemical erosion based on a temporal and / or local variability of an electrolyte's electrical conductivity comprises, in particular continuously, a calculation of a multiphase flow, wherein this calculation of a multiphase flow takes into account one or more of the following influences: a flow of the liquid electrolyte; and / or insulation by air; and / or a production of reaction gas; and / or Evaporation, in particular cavitation, of the electrolyte due to heat and / or static pressure.
6. Method according to one of the preceding claims, wherein the calculation of an electrochemical removal includes taking into account heat transfer via a multiphase flow and / or taking into account heat conduction of the component and / or heat conduction of at least one cathode and / or taking into account a temperature field of a fluid and / or a temperature field of the component and / or a temperature field of at least one cathode.
7. Method according to the preceding claim, wherein the temperature field is coupled with the electrical conductivity of the electrolyte.
8. Method according to one of the preceding claims, wherein the provided input parameters comprise a cathode voltage and / or an inlet pressure of an electrolyte and / or a cathode and / or an anode geometry and / or at least one material, in particular an electrolyte composition, and / or at least one material property, in particular a thermal conductivity, and / or at least one environmental condition, in particular a temperature.
9. Method according to any of the preceding claims, comprising the steps: - Providing (S70) validation data based on the actual manufacturing of at least one component, in particular comprising at least one blade and / or blade carrier of a gas turbine, by means of electrochemical machining; - Providing (S70) simulation data, in particular temperature data and / or electrolyte mass flow data and / or current data and / or geometry data, based on the calculation of an electrochemical erosion and / or a component geometry; - Comparing (S70) the validation data with the simulation data; and - Validating and / or adapting (S75) the simulation based on this comparison.
10. Method for designing a manufacturing process for a component, in particular comprising at least one blade and / or a blade carrier of a gas turbine, with a target geometry by means of electrochemical machining, wherein the method comprises the steps: - Determining input parameters (S10'); Simulating the manufacturing process using a method according to any of the preceding claims (S20'-S60'); - Comparing (S80) the calculated component geometry with the target geometry; these steps are repeated by varying the input parameters until a termination condition is met, in particular a predetermined number of simulation runs is reached, or a deviation between the calculated component geometry and the target geometry is less than a predetermined limit value, or at least a predetermined process requirement is met; and - Designing the manufacturing process based on the input parameters and / or values calculated during simulation.
11. Method according to the preceding claim, wherein one or more of the following input parameters are varied: cathode geometry, electrical voltage, insulation, feed rate, electrolyte mass flow, positioning of geometries involved in the process.
12. Method for manufacturing a component, in particular comprising at least one blade and / or a blade carrier of a gas turbine, with a desired geometry by means of electrochemical machining, wherein the method comprises the steps: - Design of a manufacturing process according to one of the two preceding claims; and - Manufacturing (S100) of the component using the designed manufacturing process; and / or includes the following steps: Simulating, in particular designing, a manufacturing process for the component according to one of the preceding claims; - Manufacturing (S100) of the component; and - Monitoring (S100) of the manufacturing process, comparing metrologically determined process parameters of this manufacturing with process parameters determined by simulation, in particular design.
13. Method for manufacturing a cathode, wherein the method comprises the steps: - Design of a cathode according to one of the preceding claims; and - Manufacturing (S90) a cathode based on the designed cathode.
14. System that is set up and / or comprises for carrying out a method according to any of the preceding claims: - Means of providing input parameters; and - Means for, especially repeated, Calculating electrochemical erosion based on the provided input parameters; and Calculating a component geometry based on this electrochemical removal.
15. Computer program or computer program product, wherein the computer program or computer program product, in particular stored on a computer-readable and / or non-volatile storage medium, contains instructions which, when executed by one or more computers or a system according to claim 14, cause the computer(s) or system to perform a method according to any one of claims 1 to 13.