  This work presents a novel approach to efficiently model anodic dissolution
in electrochemical machining. Earlier modeling approaches employ a strict space
discretization of the anodic surface that is associated with a remeshing
procedure at every time step. Besides that, the presented model is formulated
by means of effective material parameters. Thereby, it allows to use a constant
mesh for the entire simulation and, thus, decreases the computational costs.
Based on Faraday's law of electrolysis, an effective dissolution level is
introduced, which describes the ratio of a dissolved volume and its
corresponding reference volume. This inner variable allows the modeling of the
complex dissolution process without the necessity of computationally expensive
remeshing by controlling the effective material parameters. Additionally, full
coupling of the thermoelectric problem is considered and its linearization and
numerical implementation are presented. The model shows good agreement with
analytical and experimental validation examples by yielding realistic results.
Furthermore, simulations of a pulsed electrochemical machining process yield a
process signature of the surface roughness related to the specific accumulated
electric charge. The numerical examples confirm the simulation's computational
efficiency and accurate modeling qualities.
