Fabrication of micro-dimple arrays by AS-EMM and EMM
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In order to produce micro-dimple arrays in a metal surface with high precision, efficiency, and stability, a new processing method, air-shielding electrochemical micro-machining (AS-EMM), was proposed in this research. This method is based on the electrolyte jet micromachining and air-film protection principle. A numerical model with Gambit was created, and Fluent analyzed the flow field characteristics of the electrolyte between the multi-electrodes nozzle and the workpiece. Micro-dimple arrays were created on a 316L stainless steel surface with the consideration of the effects of machining parameters, including applied voltage and feeding speed. Compared with electrochemical micromachining (EMM), the average diameter of dimples is reduced by 31%, the ratio of dimple depth to diameter (DDR) is increased by 19%, and the surface roughness of micro-grooves is increased by 31.9%. In addition, the standard deviations of dimple diameter and depth suggest that the localization and stability by AS-EMM can be improved when using appropriate machining parameters.
KeywordsAir-shielding electrochemical micromachining Electrochemical micromachining Electrolyte jet micromachining Micro-dimple arrays Localization
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