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Electrochemical machining process for micropit arrays using a rolling device with a linear cathode and a soft mask

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Abstract

Fabricating microstructure arrays on non-planar workpiece surfaces poses significant challenges. In this paper, we propose a novel electrochemical machining process for creating micropit arrays on such surfaces using a rolling device equipped with linear cathode and soft mask. This process employs a rotary electrochemical etching method to fabricate the microstructures, addressing the limitations of traditional mask electrochemical machining, such as the inability to achieve large-scale production and difficulties in preparing curved surfaces. A set of electrolytic systems with the rolling device was constructed to machine micropit arrays on various surfaces of the metal workpieces. Numerical simulations were conducted to investigate the evolution of the electric field distribution and the variation of micropit profiles over time in the machining area, and it was determined that electrolytic machining occurs only at the micropits closest to the linear cathode When the ratio between the dimensions of the linear cathode and the mask hole is 1:3. Experimental tests were performed on the surface of a 304 stainless steel workpiece using a 10% NaNO3 electrolyte and a 0.1 mm electrode gap. The results demonstrated that micropit arrays could be successfully machined on the plane, inner and outer surface of the workpiece. Under an applied voltage of 10.5 V and a workpiece rotating speed of 0.2 r/min, the diameter of the machined micropit was 421.55±18.75 μm, the depth was 70.2±4 μm, the average etch factor (EF) was 1.16, and the roughness of the micropit was 0.625±0.205 μm, which suggested that the machined micropit arrays have high precision and uniformity. These results indicate that the machined micropit arrays exhibit high precision and uniformity. This study presents a promising strategy for high-precision batch machining of micropit arrays on both planar and curved surfaces of workpieces.

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Funding

This work is supported by the National Natural Science Foundation of China (No. 51105134), China Postdoctoral Science Foundation (No. 2020M682289), Key Research Development and Promotion Special Project (Science and Technology) of Henan Province (No. 232102221020), and Plan of Key Scientific Research Projects of Colleges and Universities in Henan Province (No. 21A460001).

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Authors and Affiliations

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

    Ge Qin, Meng Li, Lei Han, Pingmei Ming, Shen Niu, Liang Yan, Xingshuai Zheng, Xinming Zhang & Shiwei Li

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  1. Ge Qin
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  2. Meng Li
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  3. Lei Han
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  4. Pingmei Ming
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  5. Shen Niu
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  7. Xingshuai Zheng
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  8. Xinming Zhang
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  9. Shiwei Li
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Contributions

Ge Qin: conceptualization, methodology, writing—original draft, writing—review and editing, visualization, and supervision. Meng Li: investigation, visualization, writing—review and editing, and conceptualization. Lei Han: investigation and writing—original draft. Pingmei Ming: investigation and writing—review and editing. Xinmin Zhang: investigation and resources. Shen Niu: resources, conceptualization, methodology, and writing—review and editing. Liang Yan: writing—review and editing, project administration, and conceptualization. Xingshuai Zheng: writing—review and editing, project administration, and conceptualization. Shiwei Li: writing—review and editing, conceptualization, supervision, and funding acquisition.

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Correspondence to Ge Qin.

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Qin, G., Li, M., Han, L. et al. Electrochemical machining process for micropit arrays using a rolling device with a linear cathode and a soft mask. Int J Adv Manuf Technol 131, 2653–2665 (2024). https://doi.org/10.1007/s00170-023-11968-z

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  • DOI: https://doi.org/10.1007/s00170-023-11968-z

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