Intentionally-induced dynamic gas film enhances the precision of electrochemical micromachining

Zhan, Shunda; Zhao, Yonghua

doi:10.1016/j.jmatprotec.2021.117049

Cited by 20 publications

(10 citation statements)

References 29 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Sidewall insulating films , covering tool electrodes have been verified to be effective on stray-corrosion suppression. Except for the solid film, a gas-shielding film has been attempted by using high-velocity flowing compressed air to isolate the sidewall electrolyte. , Alternatively, a dynamic gas film has also been intentionally induced by pulse voltage under certain conditions . However, bubbles tend to leave the metal electrode surface with essential hydrophilic features, making the formation of a stable gas film on the electrode a major challenge.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of a Tool Electrode with Hydrophobic Features and Its Stray-Corrosion Suppression Performance for Micro-electrochemical Machining

et al. 2022

View full text Add to dashboard Cite

Micro-electrochemical machining (micro-ECM) can machine microstructures with excellent surface integrity on difficult-to-cut alloys. During micro-ECM, stray corrosion results in tapered sidewalls of machined structures. To suppress the stray corrosion, a novel tool electrode with the sidewall insulation of a gas film is proposed by fabricating the metal tool sidewall into a hydrophobic surface. The sidewall surface is designed to be characterized with spherical array cavities (radius of 500 nm) acting as the hydrophobic features, enhancing the gas-shielding effect of the gas film under electrolysis. The fabrication process of the hydrophobic sidewall is described in detail, including the self-assembly procedure of a monolayer template of Φ1 μm polystyrene microspheres, the copper-electroforming procedure for filling the microspheres’ gaps, and the removal procedure for forming spherical array cavities. The fabricated tool electrode (Φ500 μm) obtains the hydrophobic features of a contact angle of up to 138°. As a result, bubbles generated on the tool surface can form an air–electrolyte interface instead of a dispersed bubble cluster. Micro-ECM experiments of microstructures verify that the novel tool electrode can improve machining accuracy by suppressing sidewall stray corrosion.

show abstract

Section: Introductionmentioning

confidence: 99%

Fabrication of a Tool Electrode with Hydrophobic Features and Its Stray-Corrosion Suppression Performance for Micro-electrochemical Machining

et al. 2022

View full text Add to dashboard Cite

show abstract

“…Zhan et al [18] fabricated a low-surface-roughness microstructure (Ra 53.6 nm) using gas-assisted electrochemical micromachining. This method was performed by utilizing a gas-shielding electrode tool and evoking a local electrolyte flow at the gap between the tool and the workpiece for better flushing, resulting in higher surface quality.…”

Section: Introductionmentioning

confidence: 99%

Electropolishing Parametric Optimization of Surface Quality for the Fabrication of a Titanium Microchannel Using the Taguchi Method

Mahardika

Setyawan

Sriani³

et al. 2021

Machines

View full text Add to dashboard Cite

Titanium is widely used in biomedical components. As a promising advanced manufacturing process, electropolishing (EP) has advantages in polishing the machined surfaces of material that is hard and difficult to cut. This paper presents the fabrication of a titanium microchannel using the EP process. The Taguchi method was adopted to determine the optimal process parameters by which to obtain high surface quality using an L9 orthogonal array. The Pareto analysis of variance was utilized to analyze the three machining process parameters: applied voltage, concentration of ethanol in an electrolyte solution, and machining gap. In vitro experiments were conducted to investigate the fouling effect of blood on the microchannel. The result shows that an applied voltage of 20 V, an ethanol concentration of 20 vol.%, and a machining gap of 10 mm are the optimum machining parameters by which to enhance the surface quality of a titanium microchannel. Under the optimized machining parameters, the surface quality improved from 1.46 to 0.22 μm. Moreover, the adhesion of blood on the surface during the fouling experiment was significantly decreased, thus confirming the effectiveness of the proposed method.

show abstract

“…It is related to selection of optimal conditions of dissolution under the small interelectrode gap (<100 µm). The scope of the conducted research includes especially: (1) explanation of the phenomena in interelectrode gap during dissolution [5]; (2) analysis and modification of electric current distribution on the workpiece surface [6,7]; (3) selection of optimal composition of electrolyte [8]; (4) technology development, i.e., simulation of machining or the tool shape/path design [9];…”

Section: Introductionmentioning

confidence: 99%

“…(5) development of power suppliers and gap control strategy [10]; and (6) improvement of machining conditions by additional energy sources (i.e., ultrasonic vibrations [11,12]) or (7) integration with other technologies [13].…”

Section: Introductionmentioning

confidence: 99%

“…It is related to selection of optimal conditions of dissolution under the small interelectrode gap (<100 μm). The scope of the conducted research includes especially: (1) explanation of the phenomena in interelectrode gap during dissolution [ 5 ]; (2) analysis and modification of electric current distribution on the workpiece surface [ 6 , 7 ]; (3) selection of optimal composition of electrolyte [ 8 ]; (4) technology development, i.e., simulation of machining or the tool shape/path design [ 9 ]; (5) development of power suppliers and gap control strategy [ 10 ]; and (6) improvement of machining conditions by additional energy sources (i.e., ultrasonic vibrations [ 11 , 12 ]) or (7) integration with other technologies [ 13 ].…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Selected Aspects of Electrochemical Micromachining Technology Development

et al. 2021

View full text Add to dashboard Cite

The paper focuses on the fundamentals of electrochemical machining technology de-elopement with special attention to applications for micromachining. In this method, a material is removed during an anodic electrochemical dissolution. The method has a number of features which make it attractive technology for shaping parts with geometrical features in range of micrometres. The paper is divided into two parts. The first one covers discussion on: general characteristics of electrochemical machining, phenomena in the gap, problems resulting from scaling down the process and electrochemical micromachining processes and variants. The second part consists of synthetic overview of the authors’ research on localization of pulse electrochemical micromachining process and case studies connected with application of this method with use of universal cylindrical electrode-tool for shaping cavities in 1.4301 stainless steel. The latter application was conducted in two following variants: electrochemical contour milling and shaping carried out with sidewall surface of rotating tool. In both cases, the obtained shape is a function of electrode tool trajectory. Selection of adequate machining strategy allows to obtain desired shape and quality.

show abstract

Intentionally-induced dynamic gas film enhances the precision of electrochemical micromachining

Cited by 20 publications

References 29 publications

Fabrication of a Tool Electrode with Hydrophobic Features and Its Stray-Corrosion Suppression Performance for Micro-electrochemical Machining

Fabrication of a Tool Electrode with Hydrophobic Features and Its Stray-Corrosion Suppression Performance for Micro-electrochemical Machining

Electropolishing Parametric Optimization of Surface Quality for the Fabrication of a Titanium Microchannel Using the Taguchi Method

Selected Aspects of Electrochemical Micromachining Technology Development

Contact Info

Product

Resources

About