Electrochemical direct-writing machining of micro-channel array

Chen, X.L.; Dong, Bangyan; Zhang, C.Y.; Luo, Hong; Liu, J.W.; Zhang, Y.J.; Guo, Zhongning

doi:10.1016/j.jmatprotec.2018.10.014

Cited by 21 publications

(9 citation statements)

References 23 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…As the machining time increases, the discharge channels begin to build up, and a stable discharge is formed. By only turning down the machining voltage, for example, setting the machining voltage to 50 V, and keeping other machining conditions unchanged, the morphology of the machined crater does not show the special pattern of the ring-like structure [27][28][29][30].…”

Section: Characterisation Of Crater Morphology Under Discharge Condit...mentioning

confidence: 99%

Discharge Characteristics and Mechanisms of Electrolytic Discharge Processing by Jet Mask

Chen,

Wu,

et al. 2023

Coatings

View full text Add to dashboard Cite

As a novel microfabrication method, electrochemical discharge machining has remarkable effects on the forming and processing of brittle and hard materials and non-conductive materials, but little research has been done on the electrochemical discharge mode in the jet state. To fulfil the potential of this technology, innovative research on the discharge characteristics and mechanism of electrochemical discharge machining in the jet mask is proposed. A high-speed camera observation experiment was set up to record the process of the jet flow column discharge formation and penetration. Changes in the electric field of the electrolytic jet channel were analysed by simulation software, and the morphology of the machined micro-pits was observed using a microscope. A mathematical derivation of the dielectric electric field in the gas–liquid two-phase jet column reveals the mechanism of discharge channel formation in the jet state. The experiments show that when the processing voltage is 400 V, a stable continuous spark appears, realizing the unique characteristics of a large-gap long-distance discharge and a flat small circle-shaped discharge mark produced at the bottom of the crater. The actual field strength within the bubble of this model obtained by mathematical derivation is approximately 61.5 kV/cm greater than the critical field strength for air bubble breakdown in the standard state, where bubble breakdown occurs in the discharge.

show abstract

Section: Characterisation Of Crater Morphology Under Discharge Condit...mentioning

confidence: 99%

Discharge Characteristics and Mechanisms of Electrolytic Discharge Processing by Jet Mask

Chen,

Wu,

et al. 2023

Coatings

View full text Add to dashboard Cite

show abstract

“…Chen et al 39, 61 proposed a technique of producing high aspect ratio micro-dimples through a conductive mask in case of TM-ECMM with improved localisation by reducing electric field intensity at the edge of micro-dimple (another advantage of the reusable mask). Chen et al 62 recently proposed a direct-write TM-ECMM method, where the mask separates the electrolyte flow and allows the machining of multiple micro-features to take place simultaneously. Dissolution was also localised with no obvious corrosion, and micro-channels obtained were unambiguous and straight.…”

Section: Electrochemical Micro-texturingmentioning

confidence: 99%

Micro-machining: An overview (Part II)

Jain

Patel

Ramkumar

et al. 2021

Journal of Micromanufacturing

View full text Add to dashboard Cite

This article on ‘Micro-machining: An Overview (Part II)’ is in continuation to ‘Micro-machining: An Overview (Part I)’ published in this journal ( Journal of Micromanufacturing). It consists of four parts, namely, electrochemical micro-texturing, electrochemical spark micro-machining, molecular dynamics simulation and sustainability issues of micro-machining processes. Electrochemical micro-texturing (ECMTex) deals with various techniques developed for micro-texturing on different types of workpiece-surfaces, namely, flat, curved and free-form surfaces. Here, basically two categories of techniques have been reviewed, namely, with mask and without mask. It also deals with ‘single point tool micro-texturing’ which turns out to be a single-step technique requiring minimum time, but the accuracy and repeatability obtained after micro-texturing need to be critically analysed. For mass production, one needs to go for sinking kind of ECMTex processes. Electrochemical spark micro-machining (ECSMM) is an interesting hybrid (ECM+EDM) process which can be applied for electrically conducting as well as electrically non-conducting materials. However, the work reported in this article deals only with the electrically non-conducting materials for which this process was initially developed. This process has a lot of potential for theoretical work to be done. In this article, two theories of sparking/discharging have been briefly mentioned: single bubble discharging/sparking and single surface discharging. It also dicusses its applications for different types of electrically non-conducting materials. Molecular dynamics simulation (MDS) of micro-/nano-machining processes is very important, but it is very cumbersome to understand at atomic/molecular scale. In these processes, the material behaviour at micro-/nano-level machining is completely different as compared to bulk-machining (macro-machining) processes. Hence, some fundamentals of MDS have been discussed. It just gives the idea of available techniques, softwares and models for different types of processes. However, there is the need of further research work to be done for clearly understanding the MDS of micro-/nano-machining. In the end, the sustainability of micro-machining issues have been discussed, mainly based on the energy consumption per unit mass of production. It is concluded that the advanced micro-manufacturing processes are highly energy-intensive processes, and they need further studies to be done for making them more suitable from sustainability point of view. At the end of each section, some potential areas of research for enhancing the accuracy and repeatability, and minimising the production time of each process have been discussed.

show abstract

“…Bhattacharyya and Munda 11 sprayed insulating materials such as silicon nitride (Si 3 N 4 ) and silicon carbide (SiC) onto the tool sidewall in electrochemical micromachining (EMM), thereby decreasing the overcut caused by the stray current effect. Chen et al 12 integrated an insulated mask with the non-processing area of the tool and this method were able to achieve precise material removal in electrochemical direct-writing machining. Fan et al 13 applied a magnetic field in the direction perpendicular to the electric field: the effect of the resulting force on ion motion reduced stray corrosion and improved the processing conditions.…”

Section: Introductionmentioning

confidence: 99%

Electrochemical trepanning in the presence of insulating particles

Jiabao

Zhu

Jiang

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

Electrochemical trepanning is a highly effective and economic manufacturing technology and often used to process ruled surface parts in the aerospace field. Stray corrosion in electrochemical trepanning causes poor processing localization, large tip taper, and low machining accuracy. This paper presents an innovative approach to the reduction of stray corrosion in electrochemical trepanning in which ceramic particles are used to form an insulating protective layer on the machined surface and thereby inhibit harmful stray currents. The electric field distribution and contour changes during the machining process are simulated using the finite element method in COMSOL software. The results suggest that the presence of the insulating particles can dramatically improve the electric field distribution and reduce stray currents and the taper angle. A series of experiments are performed to verify the simulation results. The experiments show that the particles have a significant effect on the taper angle, reducing it from 4.03° to 2.00° at the same machining speed of 1.0 mm/min. Further experimental results show that the size and quantity of insulating particles both affect surface quality. When the particle diameter is reduced from 2.5 to 1.5 mm, the surface roughness Ra decreases from 1.32 to 1.16 μm. As the particle quantity varies from 250 to 900, a minimum value of Ra = 0.86 μm is obtained for 650 particles.

show abstract

Electrochemical direct-writing machining of micro-channel array

Cited by 21 publications

References 23 publications

Discharge Characteristics and Mechanisms of Electrolytic Discharge Processing by Jet Mask

Discharge Characteristics and Mechanisms of Electrolytic Discharge Processing by Jet Mask

Micro-machining: An overview (Part II)

Electrochemical trepanning in the presence of insulating particles

Contact Info

Product

Resources

About