Registration Number
0226U000849,
(0125U001557)
, R & D reports
Title
Development of digital twins of precision electrochemical machining processes for the production of parts for aircraft engine repair
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Розробка бази даних властивостей матеріалів для призначення режимів електрохімічного оброблення та числових моделей для розрахунку параметрів імпульсного електрохімічного оброблення
Head
Plankovskyi Serhii I., д.т.н.
Registration Date
16-01-2026
Organization
O.M. Beketov national university of urban economy in Kharkiv
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Development of digital twins of precision electrochemical machining workflows to increase the efficiency of technological preparation for the production of parts on CNC machines during aircraft engine repair
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At this stage of the research, a set of interrelated experimental and numerical studies has been conducted to establish a scientific and methodological basis for determining the regimes of pulsed electrochemical machining of materials and for the subsequent development of digital twins of these technological processes. An experimental research procedure has been developed and agreed with the industrial partner, based on the requirements of international standards DIN SPEC 91399 and VDE SPEC 90028 V1.0, and adapted to the conditions of real industrial equipment. A prototype of a special fixture has been designed and manufactured, which provides a reproducible inter-electrode gap, controlled hydrodynamic conditions of electrolyte flow, and the possibility of using standard voltage, current, pressure, and temperature sensors. The structure of a database has been developed and its population initiated; this database links the chemical composition of materials, electrolyte properties, pulsed current parameters, and experimentally determined anodic dissolution rates. Numerical models of electrolyte flow in the inter-electrode gap have been developed in the ANSYS environment using computational fluid dynamics methods; a comparative analysis of k-ε, k-ω, and SST turbulence models has been performed, and the choice of approaches has been justified as being most suitable for determining the stress–strain state of the near-surface layers of combined electrodes made of metallized plastic. The totality of the obtained results forms an integrated foundation (“methodology – fixture – database – numerical models”) for the further development of digital twins of pulsed electrochemical machining processes tailored to the needs of domestic industry and the defense-industrial complex
Product Description
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Olha P. Arsenyeva
Сергій І. Планковський
Mariia K. Sukhonos
Oleh V. Tryfonov
Yevhen V. Tsegelnyk
Vladimir Sorokin
Volodymyr V. Kombarov
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2026-01-16
