Electrochemical micro texturing on flat and curved surfaces: simulation and experiments

Patel, Divyansh Singh; Jain, V.K.; Shrivastava, Ankit; Ramkumar, J.

doi:10.1007/s00170-016-9700-3

Cited by 46 publications

(18 citation statements)

References 39 publications

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“…Chen et al [69] had applied the ECM method with TMEMM technic together with a PDMS mask and successfully produce micro dimple array on a cylindrical surface. These studies show improvement in friction coefficient [64,74] and wear [60] with fabricated micro dimples as well as able to produce a different type of micro dimple shapes [63,[60][61]. However, there is still a lack the studies of tribological behavior of ECM produced micro dimples.…”

Section: Electrochemical Machining (Ecm) and Electrical Discharge Machimentioning

confidence: 96%

“…Many of the studies recently focus on producing micro dimple array instead of single dimple [62]. Many technics have emerged such as maskless electrochemical texturing (MECT) [60,63], through-mask electrochemical micromachining (TMEMM) [58,62,[64][65][66][67], using Polydimethylsiloxane (PDMS) mask [59,61,[68][69][70][71], sandwich-like electrochemical micromachining (SLEMM) [72][73] and others [74]. Chen et al [69] had applied the ECM method with TMEMM technic together with a PDMS mask and successfully produce micro dimple array on a cylindrical surface.…”

Section: Electrochemical Machining (Ecm) and Electrical Discharge Machimentioning

confidence: 99%

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A Review of Surface Texturing in Internal Combustion Engine Piston Assembly

Azmi¹,

Mahmood²,

Ghani³

et al. 2020

IJIE

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This paper presents a brief review of surface texturing with a focus on piston assembly application. The paper begins with a general discussion on surface texturing and the manufacturing process of micro dimples. Further, it discusses the theory of hydrodynamic lift generation and the effect of parameters of micro dimples texture on the surface-to-surface friction. Finally, the effect of surface texturing on heat transfer is briefly discussed. In pursuits to improve internal combustion engine (ICE) efficiency, tribological improvement of moving surfaces by means of micro surface texturing seems to be one of the way. However, texturing parameters have to be carefully designed as it can cause detrimental effect if the designs are wrong. Studies has shown micro surface texturing at piston ring could reduce friction around 20%-50% compare with un-textured piston ring and also reduce fuel consumption at 4%. Micro Surface texturing could also improve heat transfer between the surfaces to reduce piston slap and lubrication oil temperature. As reports on the surface texturing on friction reduction and heat transfer improvement in piston assembly are relatively scarce, it is suggested that optimization of micro dimple parameters for piston skirt application and its effect on engine tribology and heat transfer characteristics to be further investigated.

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Section: Electrochemical Machining (Ecm) and Electrical Discharge Machimentioning

confidence: 96%

Section: Electrochemical Machining (Ecm) and Electrical Discharge Machimentioning

confidence: 99%

A Review of Surface Texturing in Internal Combustion Engine Piston Assembly

Azmi¹,

Mahmood²,

Ghani³

et al. 2020

IJIE

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“…Micro-ECM Groove [47], texturing on flat and curved surfaces [90], [95], drilling [8], [96], milling [23], [30], [48], [49], silicon microstructuring [97], complex internal holes [98]- [100], nanostructures [101], 3D microstructuring [102] [49],…”

Section: Research Opportunitiesmentioning

confidence: 99%

A review on process capabilities of electrochemical micromachining and its hybrid variants

Saxena

Qian

Reynaerts

2018

International Journal of Machine Tools and Manufacture

177

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Electrochemical micromachining (micro-ECM) is an unconventional micromachining technology that has capability to fabricate high aspect ratio micro-holes, micro-cavities, microchannels and grooves on conductive and difficult-to-cut materials. Both academia and industry have the consensus that it offers promising machining performance especially in terms of high surface finish, no tool wear and absence of thermally induced defects. Furthermore in order to machine novel materials with extreme properties, novel hybrid electrochemical micromachining technologies are under development. With these hybrid micro-ECM technologies, capabilities of micro-ECM can be expanded by combining it with other processes. To fully exploit the potential as well as improve micro-ECM technology and related hybrid processes, a wide spectrum of multidisciplinary knowledge is needed. The present review systematically discusses process capabilities and research developments of electrochemical micromachining and its hybrid variants considering knowledge of both basic and applied research fields. After few introductory review articles in prior state of the art, this review fills an important gap in research literature by presenting first time an extended literature source with a wide coverage of recent research developments in electrochemical micromachining technology and its hybrid variants. This paper outlines the research and engineering developments in electrochemical micromachining technology and its hybrid variants, review of the related concepts, aspects of tooling, advanced process capabilities and process energy sources. It also provides new sights into technological understanding of micro-ECM technology which will be helpful in future engineering developments of this technology.

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“…A single electrode-based electrochemical micromachining is being widely used for hole drilling, 21 milling, 22, 23 micro-tools fabrication, 24 parting and structuring. 25 Single tool-based micro-texturing methodology opts from the earlier research of Patel et al 26, 27 where predesigned micro-tool is employed with zero feed at the minimum inter-electrode gap (IEG) which leads to the formation of bell-shaped micro-dimples.…”

Section: Electrochemical Micro-texturing (Ecmtex)mentioning

confidence: 99%

Numerical modelling of ECMM of micro-dimples considering the effect of 3-phase electrolyte

Prashanth

Patel

Jain

et al. 2019

Journal of Micromanufacturing

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Electrochemical surface texturing is a complex process consisting of two-phase fluid dynamics, unsteady state heat transfer, mass transfer, electrochemistry, etc., between moving boundaries. There are no anode shape prediction models for surface texturing because of the complications involved in the process. The models available for electrochemical micromachining (ECMM) are incomplete because most of them ignore the influence of sludge and gas bubbles produced during the electrochemical dissolution. In this article, a modified anode shape prediction model considering the evolution of heat, sludge and H2 bubbles have been proposed for ECMM of micro-dimples. Comparison of simulated and experimental anode profiles reveals a satisfactory agreement between the two. In addition, a comparison has been made between the proposed model and the models, which do not consider the effect of generation of sludge and gas bubbles on the conductivity of the electrolyte.

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Electrochemical micro texturing on flat and curved surfaces: simulation and experiments

Cited by 46 publications

References 39 publications

A Review of Surface Texturing in Internal Combustion Engine Piston Assembly

A Review of Surface Texturing in Internal Combustion Engine Piston Assembly

A review on process capabilities of electrochemical micromachining and its hybrid variants

Numerical modelling of ECMM of micro-dimples considering the effect of 3-phase electrolyte

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