Jet electrochemical machining of micro dimples with conductive mask

Chen, X.L.; Dong, Bangyan; Zhang, C.Y.; Wu, Ming; Guo, Ziwen

doi:10.1016/j.jmatprotec.2018.02.035

Cited by 34 publications

(17 citation statements)

References 15 publications

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“…The mask used had through holes of 200 μm diameter on stainlesssteel samples. The machining localisation was improved with the use of a conductive mask over an insulated mask, at the cost of a reduction in current efficiency [18]. Comparatively, this study produced dimples 240 μm wide by 85 μm deep, no better than those achieved by Hackert-Oschätzchen et al [19] without the use of a mask.…”

Section: Increase In Current Improves Surface Roughness Valuesmentioning

confidence: 66%

See 1 more Smart Citation

A review of physical experimental research in jet electrochemical machining

Kendall

Bartolo

Gillen

et al. 2019

Int J Adv Manuf Technol

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Jet electrochemical machining (Jet-ECM) is a non-traditional machining process that has developed rapidly since its introduction in the 1980s with progress being made in micro-machining and surface finishing. This paper critically reviews the development of physical experimental work in Jet-ECM and corresponding hybrid technologies and their applications, e.g. laser-and air-assisted Jet-ECM. In addition to discussing the merits of the physical experimental research, the paper concludes with research challenges in the future of Jet-ECM development.

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Section: Increase In Current Improves Surface Roughness Valuesmentioning

confidence: 66%

“…Chen et al [18] proposed a method of machining micro dimples through the use of a conductive mask. The use of a conductive mask was thought to reduce the intensity of the electric field around the edge of the dimple.…”

Section: Increase In Current Improves Surface Roughness Valuesmentioning

confidence: 99%

A review of physical experimental research in jet electrochemical machining

Kendall

Bartolo

Gillen

et al. 2019

Int J Adv Manuf Technol

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show abstract

“…The auxiliary anode was proposed to reduce the marginal effect of the electric field on the workpiece, thereby improving the machining accuracy of the microstructure [27]. Chen et al [28] developed a method of JEM with a conductive mask to generate micro-dimples, which evidently reduced the overcut and enhanced the machining localization.…”

Section: Instructionmentioning

confidence: 99%

Jet Electrochemical Micromachining of Micro-Grooves with Conductive-Masked Porous Cathode

et al. 2020

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Surface structures with micro-grooves have been reported to be an effective way for improving the performance of metallic components. Through-mask electrochemical micromachining (TMEMM) is a promising process for fabricating micro-grooves. Due to the isotropic nature of metal dissolution, the dissolution of a workpiece occurs both along the width and depth. Overcut is generated inevitably with increasing depth, which makes it difficult to enhance machining localization. In this paper, a method of electrochemical machining using a conductive masked porous cathode and jet electrolyte supply is proposed to generate micro-grooves with high machining localization. In this configuration, the conductive mask is directly attached to the workpiece, thereby replacing the traditional insulated mask. This helps in achieving a reduction in overcut and an improvement in machining localization. Moreover, a metallic nozzle is introduced to supply a jetted electrolyte in the machining region with enhanced mass transfer via a porous cathode. The simulation and experimental results indicate that as compared with an insulated mask, the use of a conductive mask weakens the electric field intensity on both sides of machining region, which is helpful to reduce overcut and enhance machining localization. The effect of electrolyte pressure is investigated for this process configuration, and it has been observed that high electrolyte pressure enhances the mass transfer and improves the machining quality. In addition, as the pulse duty cycle is decreased, the dimensional standard deviation and roughness of the fabricated micro-groove are improved. The results suggest the feasibility and reliability of the proposed method.

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“…The machining depth of generated micropatterns is very less. The conductive mask jet electrochemical machining method is employed to reduce the undercut of the array of micro impressions and improve the machining localization [11]. But, this method is prolonged and expensive due to fabrication of one by one circular impression in the micro dimple array.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of array of micro circular impressions using different electrolytes by maskless electrochemical micromachining

Kunar

Rajkeerthi²,

Mandal

et al. 2020

Manufacturing Rev.

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Maskless electrochemical micromachining (EMM) is a prominent technique for producing the array of micro circular impressions. A method for producing the array of micro circular impressions on stainless steel workpiece applying maskless electrochemical micromachining process is presented. The experimental setup consists of maskless EMM cell, electrode holding devices, electrical connections of electrodes and constricted vertical cross flow electrolyte system to carry out the experimental investigation. One non-conductive masked patterned tool can produce more than twenty six textured samples with high quality. A mathematical model is developed to estimate theoretically the radial overcut and machining depth of the generated array of micro circular impressions by this process and corroborate the experimental results. This study provides an elementary perceptive about maskless EMM process based on the effects of EMM process variables i.e. pulse frequency and duty ratio on surface characteristics including overcut and machining depth for NaCl, NaNO3 and NaNO3 + NaCl electrolytes. From the experimental investigation, it is observed that the combined effect of lower duty ratio and higher frequency generates the best array of micro circular impressions using the mixed electrolyte of NaNO3 + NaCl with mean radial overcut of 23.31 µm and mean machining depth of 14.1 µm.

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Jet electrochemical machining of micro dimples with conductive mask

Cited by 34 publications

References 15 publications

A review of physical experimental research in jet electrochemical machining

A review of physical experimental research in jet electrochemical machining

Jet Electrochemical Micromachining of Micro-Grooves with Conductive-Masked Porous Cathode

Fabrication of array of micro circular impressions using different electrolytes by maskless electrochemical micromachining

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