Investigation on surface structuring generated by electrochemical micromachining

Kunar, S.; Bhattacharyya, B.

doi:10.1007/s40436-017-0186-5

Cited by 18 publications

(4 citation statements)

References 12 publications

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“…Compared to the aforementioned methods, electrochemical micromachining (EMM) [11] is a promising method for preparing micro cavities [12], as it has unique advantage such as a good control on cavity profile, the potential for multi-response optimization [13], independence of material hardness [14] and toughness [15], absence of a heat-affected layer, lack of process related tool wear and burrs, and a high throughput capability. Throughmask electrochemical micromachining (TMEMM) is a promising method for generating array-like surface microstructures.…”

Section: Introductionmentioning

confidence: 99%

Multi-ion Based Modelling and Experimental Investigations on Consistent and High-throughput Generation of Micro Cavity Array by Mask Electrolyte Jet Machining

Wu¹,

Guo²,

Qian³

et al. 2022

Preprint

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The controllability and consistency in the fabrication of micro-textures on large-scale remains a challenge for existing production processes. Mask electrolyte jet machining (MEJM) is an alternative to Jet-ECM for controllable and high-throughput surface microfabrication with more consistency of dimensional tolerances. This hybrid configuration combines the high-throughput of masked-ECM and the adjustable flow-field of jet-ECM. In this work, a duckbill jet nozzle was introduced to make MEJM more capable of batch micro-structuring. A multiphysics model was built to simulate the distribution of electrochemical reaction ions, the cur- rent density distribution and the evolution of the shape of the machined cavity. Experimental investigations are presented showing the influence of the machining voltage and nozzle moving speed on the micro cavity. Several 35 ×35 micro cavity arrays with a diameter of 24.92 − 11.73 µm and depth of 15.86 − 7.24 µm are generated on 304 stainless steel.

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Section: Introductionmentioning

confidence: 99%

Multi-ion Based Modelling and Experimental Investigations on Consistent and High-throughput Generation of Micro Cavity Array by Mask Electrolyte Jet Machining

Wu¹,

Guo²,

Qian³

et al. 2022

Preprint

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“…studied the effect of pulse width on electrochemical machining grooves. The results show that the depth of micro-ring grooves is 60 um when the pulse width is 0.1 s. Kunar et al [8]. improved the surface quality of the workpiece by optimizing the process parameters such as duty cycle, pulse frequency, processing voltage and electrolyte concentration.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on the Inner Wall Ring Groove of 1J116 Soft Magnetic Alloy Based on Electrochemical Machining

Bian¹,

Ma²,

Ai³

et al. 2019

Proceedings of the 2019 International Conference on Precision Machining, Non-Traditional Machining and Intelligent Manufacturin

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In this study, electrochemical processing was introduced into the inner wall ring groove of 1J116 soft magnetic alloy to obtain higher processing precision. A single factor experimental study was carried out for the processing and forming laws and mechanisms. The effects of pulse voltage, duty cycle, pulse frequency, and electrolyte pressure on material removal rate and groove width and groove depth of the inner wall were analyzed. The results show that the effects of pulse voltage, duty cycle, pulse frequency and inlet pressure on the material removal rate are positively correlated. The groove width and groove depth of the inner wall ring groove increase with the increase of process parameters, in order to achieve higher The processing accuracy requires a reasonable range of process parameters.

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“…Since the German MPG invented the nanosecond ultrashort pulse electrochemical machining in 2000 [ 7 ], the United States, Japan, Korea, and other industrialized countries in the world have invested heavily in micro electrochemical machining research. For example, Kunar machined a dimple array of micro holes with good geometrical shape [ 8 ]; Rathod used a disk-shaped electrode to conduct micro-electrolytic milling experiments, and successfully produced a series of microgrooves such as reverse tapered, barrel shaped, double stepped, and spherical [ 9 ]; Rathod researched the influence of electrochemical micro machining (EMM) parameters like tool feed rate, applied voltage, duty ratio, pulse frequency, and electrolyte concentration on the machining accuracy of a 500 μm-deep microgroove in stainless steel, and a high-quality microgroove with 55 μm width overcut and 10 μm-depth overcut with an aspect ratio of 2.31 was fabricated using an in situ-fabricated tungsten microtool of 110 μm diameter [ 10 , 11 ]; Yuan used current feedback to electrode position, and successfully fabricated array grooves with the width of 6 μm [ 12 ]; Xu added an adjustable inductance element in the equivalent circuit of the electrochemical micromachining to form a coupled fluid-electric circuit. With a tungsten electrode with a diameter of 15 μm, the multi-order 3D microstructure was obtained.…”

Section: Introductionmentioning

confidence: 99%

Experimental Research on Machining Localization and Surface Quality in Micro Electrochemical Milling of Nickel-Based Superalloy

et al. 2018

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Micro electrochemical machining is becoming increasingly important in the microfabrication of metal parts. In this paper, the machining characteristics of micro electrochemical milling with nanosecond pulse were studied. Firstly, a mathematical model for the localization control of micro electrochemical milling with nanosecond pulse was established. Secondly, groups of experiments were conducted on nickel-based superalloy and the effects of parameters such as applied voltage, pulse on time, pulse period, electrolyte concentration and electrode diameter on machining localization and surface roughness were analyzed. Finally, by using the optimized machining parameters, some 2D complex shapes and 3D square cavity structures with good shape precision and good surface quality were successfully obtained. It was proved that the micro electrochemical milling with nanosecond pulse technique is an effective machining method to fabricate metal microstructures.

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Investigation on surface structuring generated by electrochemical micromachining

Cited by 18 publications

References 12 publications

Multi-ion Based Modelling and Experimental Investigations on Consistent and High-throughput Generation of Micro Cavity Array by Mask Electrolyte Jet Machining

Multi-ion Based Modelling and Experimental Investigations on Consistent and High-throughput Generation of Micro Cavity Array by Mask Electrolyte Jet Machining

Experimental Study on the Inner Wall Ring Groove of 1J116 Soft Magnetic Alloy Based on Electrochemical Machining

Experimental Research on Machining Localization and Surface Quality in Micro Electrochemical Milling of Nickel-Based Superalloy

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