Sandwich-like electrochemical micromachining of micro-dimples using a porous metal cathode

Zhang, Xifang; Qu, Ningsong; Fang, Xiaolong

doi:10.1016/j.surfcoat.2017.01.035

Cited by 32 publications

(9 citation statements)

References 22 publications

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“…In order to evacuate bubbles and some insoluble electrolytic products as well as optimize the cathode structure of conventional SLEMM, Zhang et al [25] proposed a process scheme of the open reaction unit by using a porous cathode. Ming et al [26] analyzed and verified the electric field distribution characteristics of the above method and fabricated micro-dimples arrays of dimensional uniformity on the cylindrical workpiece surface.…”

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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Section: Instructionmentioning

confidence: 99%

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

et al. 2020

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“…Attempts have been made to enhance the quality and depth of the fabricated dimples by using porous metal cathode in place of solid metal cathode so as to allow gases to escape from the machining zone. 44 To further enhance the machining accuracy of microdimples, the flow of electrolyte was made in the lateral direction through porous metal cathode. 45 Furthermore, it is claimed that a better accuracy is achieved in case of SLECMM, which can be explained on the basis of accumulation of gas bubbles and sludge along the machined surface and edges because these reaction products have no way to escape.…”

Section: Electrochemical Micromachiningmentioning

confidence: 99%

Micromachining: An overview (Part I)

Jain

Balasubramaniam

Mote

et al. 2020

Journal of Micromanufacturing

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This article gives classification of micromanufacturing in general and micromachining processes in particular. For different micromachining processes, one can have different kinds of operations through which different features, shapes, accuracy, precision, and dimensions can be achieved. This article as Part I reports an overview of only three processes as diamond turn machining (a class of traditional micromachining processes), electrochemical micromachining, and focused-ion-beam micromachining (a class of advanced micromachining processes). About all these three processes, a brief introduction to the mechanisms of material removal is reported followed by the new developments in each process which are discussed independently. In various sections, some areas where research work needs to be done are identified and very briefly discussed.

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“…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%

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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Sandwich-like electrochemical micromachining of micro-dimples using a porous metal cathode

Cited by 32 publications

References 22 publications

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

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

Micromachining: An overview (Part I)

A Review of Surface Texturing in Internal Combustion Engine Piston Assembly

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