Sandwich-like electrochemical micromachining of micro-dimples

Zhang, Xifang; Qu, Ningsong; Chen, Xiaolei

doi:10.1016/j.surfcoat.2016.05.088

Cited by 49 publications

(15 citation statements)

References 22 publications

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“…It was further discovered from Figure.14 that the minimum CV depth and CV diameter are 5.4% and 1.9%, respectively, when the appropriate combination of the applied voltage (8.5 V) and the moving speed (0.5 m/s) are used, showing a considerably narrower variation range of 43.7-51.3 μm in depth and 370.9-394.9 μm in diameter. To the best knowledge of the authors from the reported literature, the CV values obtained in our study are sufficiently small to reach the levels that were obtained from the standard photolithographic photoresist electrochemical machining process [20,21,28], and they are also smaller than those achieved with the first version foamed cathode TMEMM process [30].…”

Section: Effect Of the Applied Voltages And The Moving Speed Of The Mmentioning

confidence: 44%

Through-Mask Electrochemical Micromachining with Reciprocating Foamed Cathode

et al. 2020

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A through-mask electrochemical micromachining process with a foamed cathode (foamed-cathode through-mask electrochemical micromachining (TMEMM)) has recently been proposed involving micro-scale surface microstructures with a high geometric consistency that are fabricated on the curved-surface workpiece. In this paper, to make the foamed-cathode TMEMM process more cost-efficient in the applications, significant modifications are made to this process and an upgraded version of the foamed-cathode TMEMM process is developed. In this modified process, the sandwich-like unit (including the foamed cathode, mask, and workpiece) is closely assembled by the magnetic field force instead of the conventionally-used mechanical force and is kept moving up-and-down inside the electrolyte, avoiding the use of the traditional pump-driven circulation for the electrode process. Experiments are carried out to evaluate the machining effect of this modified TMEMM for fabricating micro-dimples. The research results verify that this modified TMEMM process can produce highly uniform micro-dimples whose minimum CV (coefficient of variation) values in depth and in diameter are 5.4% and 1.9%, respectively, with smooth surfaces of the minimum Ra being 0.21-0.35 µm. These values are smaller than those previously reported. This results in the positive effects on the mass transfer driven by magnetohydrodynamic convection induced by the magnetic field within the interelectrode and the foamed electrode.Micromachines 2020, 11, 188 2 of 14 is very tedious and expensive. In addition, the photoresist through-mask cannot be well formed on the curved surface; as a result, the traditional TMEMM process is somewhat limited in industrial applications. Consequently, effort has been made to facilitate the preparation of the through-mask by researchers. For instance, Landolt et al. and Chauvy et al. [13,14] employed patterned oxide film as the through-mask to texturize titanium. Asoh et al. [15] presented a novel TMEMM process to accomplish the formation of large-scale microstructures just by using the self-assembled polystyrene colloidal crystal particles as the through-mask. In an unusual way, Schönenberger et al. [16] and Costa et al. [17,18] bonded the through-mask to the cathode surface instead of the workpiece surface (anode) to carry out the micro-pattern transferring operation. Recently, further optimized the preparation of the through-mask of this kind of cathode-typed TMEMM by using the removable dry film through-mask, resulting in high cost-effectiveness.Unlike the conventional TMEMM processes using the bonded through-mask, a removable and reusable through-mask electrochemical machining process was exploited by Zhu et al. [22][23][24]. In this novel process, the mask is pressed mechanically against the workpiece, and thus, it can be reused repeatedly, showing a favorable operational convenience and cost-effective superiority. Additionally, in this novel process, Qu et al. [25][26][27][28] used polydimethylsiloxane (PDMS) film as the reusable mask d...

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Section: Effect Of the Applied Voltages And The Moving Speed Of The Mmentioning

confidence: 44%

Through-Mask Electrochemical Micromachining with Reciprocating Foamed Cathode

et al. 2020

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“…It is worth pointing out that ECPTM also suffers from severe stray corrosion on both sides of the micro-groove due to the unprotected surface of the workpiece. Zhang et al [24] developed a sandwich-like electrochemical micromachining (SLEMM) technology for reducing overcut and improving the dimensional uniformity of micro-dimples by enabling uniform distribution of the electric field in the machining region. However, the generation of bubbles and accumulation of insoluble products in the machining region suppress the dissolution of the workpiece.…”

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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“…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

Cited by 49 publications

References 22 publications

Through-Mask Electrochemical Micromachining with Reciprocating Foamed Cathode

Through-Mask Electrochemical Micromachining with Reciprocating Foamed Cathode

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

A Review of Surface Texturing in Internal Combustion Engine Piston Assembly

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