Abstract
Through-mask electrochemical micromachining (TMEMM) is a promising method to prepare micro dimples on the surface of metallic parts. However, the workpiece is machined one by one in traditional TMEMM. This paper introduced bidirectional pulse to TMEMM to improve the machining efficiency. Two masked workpieces were placed face to face, and connected to the ends of the bidirectional pulse power supply. Along with the change of the pulse direction, the polarities of the two workpieces were interchanged periodically, and micro dimples could be prepared on both workpieces at one time. The simulation and experiment results indicated that with bidirectional pulse mode, micro dimples with same the profile can be prepared on two workpieces at one time, and the dimension of micro dimple was smaller than that with unidirectional pulse mode. In bidirectional pulse current, the pulse frequency and pulse duty cycle played an important role on the preparation of micro dimple. With high pulse frequency and low pulse duty cycle, it is useful to reduce the undercut of micro dimple and improve the machining localization. With the pulse duty cycle of 20% and pulse frequency of 10 kHz, micro dimples with etch factor (EF) of 3 were well prepared on both workpieces surface.
Highlights
Accepted: 14 September 2021It has been reported that surface texture with the size of micro and nano scale plays a significant role on the regulation of surface property [1]
In order to compare the difference of micro dimples generated with different modes, the comparison experiments were designed with the same machining parameters: the applied voltage of 30 V, pulse duty cycle of 20%, pulse frequency of 4 kHz, and the real machining time of 15 s
There was a dimensional difference of 20 μm between the two machining modes, and the material removal amount with was bidirectional pulse current was slightly lower than that with unidirectional pulse current
Summary
It has been reported that surface texture with the size of micro and nano scale plays a significant role on the regulation of surface property [1]. Through-mask electrochemical micromachining (TMEMM) is a popular approach for the generation of micro dimples, in which the workpiece is coated of insulated photoresist with patterned through-structure as the mask, the exposed area on the workpiece will be dissolved, and micro dimples are manufactured. With this method, micro dimples with the diameter of 30 μm were well prepared on a titanium surface [9]. A mathematical model was built to analyze the evolution process of the micro dimple with bidirectional pulse, and the experiments were performed to verify the proposed method
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