Generation of Microtextured Characteristics using Maskless Electrochemical Micromachining

Abstract

To minimize and control friction and wear, the manufacture of microtextured characteristics on circular micropatterns is an innovative approach to extend the life of mechanical systems and components and enhance their reliability and performance. The form, size, and surface quality of circular micropatterns developed on stainless steel surfaces using maskless electrochemical micromachining directly affect the service life and function of textured surface. This article presents the experimental study on the generation by electrochemical micromachining of circular micropatterns on stainless steel. The effect of process variables such as inter-electrode gap (IEG), flow velocity and machining time on current density, current efficiency, material removal rate (MRR), surface roughness, and diametric taper angle are examined during the generation of circular micropatterns. The best parameters obtained from the experimental results are 100μm IEG, 4.4 m/s flow velocity and 3 minutes machining time for producing this micropattern. An attempt is also made to analyze the optical and 3D images of circular micropattern from the experimental results.