Abstract
To realize the electrochemical etching of a micro spiral cylindrical electrode, a new method of rotating electrochemical etching is proposed, and its process is further studied. First, according to the electrochemical etching principle, the machining mechanism of rotating electrochemical etching of a micro spiral cylindrical electrode is introduced. Second, based on the spiral vortex theory in the Taylor-Couette system, the effect of the high-speed rotating cylindrical microelectrode on its external flow field is analyzed. Third, the effects of rotation direction, rotation speed, machining voltage, and machining time on the thread structure are analyzed by experiments. Finally, a spiral cylindrical microelectrode with good surface thread shape is fabricated within two minutes by using the optimized machining parameters. It is proved that the rotating electrochemical etching method is an easy way to fabricate a micro spiral cylindrical electrode with high efficiency and low cost.
Highlights
With the combination of numerical control technology and micromachining, the tool microelectrodes in electrochemical micromachining (EMM) and micro electrochemical discharge machining play the same role as those in traditional machining
Liu used one pulse electro discharge to melt the tip of the multi-stepped cylindrical electrode to form a spherical end with the spherical diameter of ∅ 10 μm and the shank diameter of ∅ 6 μm [1,2]
There are few studies on spiral microelectrodes, and the main difficulty in machining spiral microelectrode fabricating a spiral groove on the surface of the cylindrical microelectrode
Summary
With the combination of numerical control technology and micromachining, the tool microelectrodes in electrochemical micromachining (EMM) and micro electrochemical discharge machining (micro-ECDM) play the same role as those in traditional machining. Many scholars have fabricated specially shaped tools, such as a disk microelectrode, micro spherical electrode, multi-stepped cylindrical microelectrode, array electrodes, spiral microelectrode, etc., based on cylindrical electrodes, which can improve the machining accuracy and efficiency. The aspect ratio of the multi-stepped cylindrical microelectrode is relatively large, and the diameter of the terminal electrode can be machined to several microns stably, which can meet some micro size machining. In this paper, based on the conventional EMM process and the effect of electrode rotation on the flow field and diffusion layer around the electrode surface, a new method for machining spiral cylindrical microelectrodes with high machining efficiency, low machining cost, and simple operation is proposed, and the shape and surface quality of the machined microelectrode are good
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