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Through-Mask Electrochemical Micromachining with Reciprocating Foamed Cathode

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 workpi...

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Autores principales: Zhao, Chenhao, Ming, Pingmei, Zhang, Xinmin, Qin, Ge, Shen, Jiwen, Yan, Liang, Zheng, Xingshuai, Cao, Jun
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2020
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7074634/
https://www.ncbi.nlm.nih.gov/pubmed/32054003
http://dx.doi.org/10.3390/mi11020188
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author Zhao, Chenhao
Ming, Pingmei
Zhang, Xinmin
Qin, Ge
Shen, Jiwen
Yan, Liang
Zheng, Xingshuai
Cao, Jun
author_facet Zhao, Chenhao
Ming, Pingmei
Zhang, Xinmin
Qin, Ge
Shen, Jiwen
Yan, Liang
Zheng, Xingshuai
Cao, Jun
author_sort Zhao, Chenhao
collection PubMed
description 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.
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spelling pubmed-70746342020-03-20 Through-Mask Electrochemical Micromachining with Reciprocating Foamed Cathode Zhao, Chenhao Ming, Pingmei Zhang, Xinmin Qin, Ge Shen, Jiwen Yan, Liang Zheng, Xingshuai Cao, Jun Micromachines (Basel) Article 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. MDPI 2020-02-11 /pmc/articles/PMC7074634/ /pubmed/32054003 http://dx.doi.org/10.3390/mi11020188 Text en © 2020 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Zhao, Chenhao
Ming, Pingmei
Zhang, Xinmin
Qin, Ge
Shen, Jiwen
Yan, Liang
Zheng, Xingshuai
Cao, Jun
Through-Mask Electrochemical Micromachining with Reciprocating Foamed Cathode
title Through-Mask Electrochemical Micromachining with Reciprocating Foamed Cathode
title_full Through-Mask Electrochemical Micromachining with Reciprocating Foamed Cathode
title_fullStr Through-Mask Electrochemical Micromachining with Reciprocating Foamed Cathode
title_full_unstemmed Through-Mask Electrochemical Micromachining with Reciprocating Foamed Cathode
title_short Through-Mask Electrochemical Micromachining with Reciprocating Foamed Cathode
title_sort through-mask electrochemical micromachining with reciprocating foamed cathode
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7074634/
https://www.ncbi.nlm.nih.gov/pubmed/32054003
http://dx.doi.org/10.3390/mi11020188
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