Pulsed electrochemical micromachining for generating micro-dimple arrays on a cylindrical surface with a flexible mask

Chen, Xiaolei; Qu, Ningsong; Li, Hansong; Xu, Zhengyang

doi:10.1016/j.apsusc.2015.03.087

Cited by 40 publications

(17 citation statements)

References 18 publications

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“…The depth of micro-dimple sharply reduced from 20 to 6.4 µm at an effective machining time of 15 s when the duty cycle increased from 20% to 80%. 23 Figure 8 shows scanning electron microscopic images and three-dimensional profiles of micro-dimple arrays with different pulse duty cycles. It can be concluded that both pulse current and direct current are capable of generating micro-dimple arrays with good profiles.…”

Section: Resultsmentioning

confidence: 99%

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Electrochemical micromachining of large-area micro-dimple arrays with high machining accuracy

Hou

Chen

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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Surface textures, especially micro-dimple arrays, can significantly improve the friction performance of engineering parts. Through-mask electrochemical micromachining is an effective method for generating micro-dimple arrays. In this article, a new method is introduced to fabricate a large-area polydimethylsiloxane mask containing micro through-holes. Using this technique, a stainless steel mould with micro-pillar arrays is generated by wire electrical discharge machining. A combination of pressure and weight of electrolyte is then proposed to keep the polydimethylsiloxane mask closely attached to the workpiece, which helps to achieve high machining accuracy. The effects of applied voltage, effective machining time and pulse duty cycle on the micro-dimples are investigated. The profiles of the micro-dimples are not sensitive to applied voltage, but pulse duty cycle is a significant factor influencing the depth of the micro-dimples. Micro-dimples of width 95 µm, depth 19 µm and a machining area of diameter 40 mm are successfully generated using a polydimethylsiloxane mask, and the standard deviations of the micro-dimple width and depth are only 0.84 and 0.23 µm, respectively. The present experiments verify that it is feasible to obtain large-area micro-dimple arrays with high machining accuracy using this technique.

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Section: Resultsmentioning

confidence: 99%

“…In previous work, the maximum machining area of a PDMS mask, prepared using an SU-8 mould, has only had a diameter of 10 mm. 22,23 Although large-area micro-dimple arrays are potentially useful in engineering applications, it is still a challenge to prepare sufficiently large-area PDMS mask with micro through-holes.…”

Section: Introductionmentioning

confidence: 99%

Electrochemical micromachining of large-area micro-dimple arrays with high machining accuracy

Hou

Chen

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…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. 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].…”

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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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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“…8, 9 In general, through-mask ECM is a globally well-known technology employed for micro-dimples fabrication for applying the textures in large scale. 10–13 On the other hand, a mask-less process of multiple micro-electrode arrays (fabricated through Wire-ECM or Wire-EDM) of generating micro-dimples is multiple tools-based electrochemical texturing. Once the micro-electrode array is developed, it can be used by direct writing method for creating micro-patterns (such as channels and pillars) or by sinking to produce micro-dimples or micro-hole arrays.…”

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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Pulsed electrochemical micromachining for generating micro-dimple arrays on a cylindrical surface with a flexible mask

Cited by 40 publications

References 18 publications

Electrochemical micromachining of large-area micro-dimple arrays with high machining accuracy

Electrochemical micromachining of large-area micro-dimple arrays with high machining accuracy

A Review of Surface Texturing in Internal Combustion Engine Piston Assembly

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

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