Influence of maskless electrochemical micromachining process parameters during microtexturing

Abstract

Abstract Maskless electrochemical micromachining (EMM) is a prospective procedure for elevated precision microtexturing. Particularly the microtexturing of substrates without any mechanical influence or heat affect is a substantial characteristic for this process. Moreover, the anodic dissolution performance of job material is only characterized by its electrochemical features. This creates maskless EMM an alternative procedure for electrochemically hard to machine materials. Maskless EMM method with developed vertical cross flow method has been recommended involving microtexturing with higher symmetrical uniformity that are produced on stainless steel (SS304) surface. In this paper, maskless EMM method is a promising cost-efficient substitute for microtexturing containing rectangular micropatterns. The advanced setup has the developed machining cell, flow system and unique electrical connection unit. The machining unit has fixturing arrangements of electrodes, flow system, and electrical connection arrangement. Within the machining unit, the advanced flow scheme is a vertical cross flow system that aids in the fabrication of high-quality microtextured surface. One coated textured tool can produce many rectangular micropatterns with high quality. The effect of process parameters such as electrolyte concentration, machining time, and inter electrode gap (IEG) is evaluated on surface roughness (Ra), length overcut, machining depth and width overcut when fabricating micropatterns is investigated. The best process variables i.e., 50 μm IEG, 6 s machining time and 15 g/l electrolyte concentration manufacture good quality micropatterns.