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Investigation of foamed cathode through-mask electrochemical micromachining developed for uniform texturing on metallic cylindrical surface

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Abstract

Surface texturing with micro-dimples has been proved to be an effective approach in many fields to improve the functionalities and performances of some mechanical components. Through-mask electrochemical micromachining (TMEMM) is a popular technique to create textures on metallic surface, but it is still very challenging to be used to texture curved surface. In this paper, a novel TMEMM process was proposed to generate micro-dimple array on the cylindrical surface. In this TMEMM process, a foamed metal film with a good pliancy performance and a huge number of interconnected micropores is introduced to serve as the cathode, which is further integrated with the reusable through-mask and workpiece to form a sandwich-like assembly. The current distribution within each region being machined and its correlation with the geometric dimensions of through-hole, as well as with the relative location of the through-hole in the mask, are analyzed numerically. With this TMEMM process, a great number of micro-dimples with a good uniformity in their geometric dimensions can be produced both on the planar and the entire 360° cylindrical workpiece surfaces in only one operation, showing the minimum coefficient of variation of the dimple’s depth and diameter being 5.6 and 2.4%, respectively. The reasons for such a favorable result are interpreted theoretically. The proposed TMEMM process here could have a great potential in generating geometrically consistent surface textures on the curved surface efficiently and low-costly.

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Acknowledgements

This work was financially supported by the National Natural Science Foundation of China (No. 51475149), Plan for Scientific Innovation Talent of Henan Province (No. 154100510008), and the Program for Science & Technology Innovation Team in Henan Polytechnic University (No. T2014-1).

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Authors and Affiliations

  1. School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo, 454000, China

    Pingmei Ming, Chenhao Zhao, Xinmin Zhang, Xinchao Li, Ge Qin & Liang Yan

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  1. Pingmei Ming
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  2. Chenhao Zhao
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  3. Xinmin Zhang
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  4. Xinchao Li
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  5. Ge Qin
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  6. Liang Yan
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Correspondence to Pingmei Ming or Xinmin Zhang.

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Ming, P., Zhao, C., Zhang, X. et al. Investigation of foamed cathode through-mask electrochemical micromachining developed for uniform texturing on metallic cylindrical surface. Int J Adv Manuf Technol 96, 3043–3056 (2018). https://doi.org/10.1007/s00170-018-1755-x

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  • DOI: https://doi.org/10.1007/s00170-018-1755-x

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