Fabrication of array of micro circular impressions using different electrolytes by maskless electrochemical micromachining

Abstract

Maskless electrochemical micromachining (EMM) is a prominent technique for producing the array of micro circular impressions. A method for producing the array of micro circular impressions on stainless steel workpiece applying maskless electrochemical micromachining process is presented. The experimental setup consists of maskless EMM cell, electrode holding devices, electrical connections of electrodes and constricted vertical cross flow electrolyte system to carry out the experimental investigation. One non-conductive masked patterned tool can produce more than twenty six textured samples with high quality. A mathematical model is developed to estimate theoretically the radial overcut and machining depth of the generated array of micro circular impressions by this process and corroborate the experimental results. This study provides an elementary perceptive about maskless EMM process based on the effects of EMM process variables i.e. pulse frequency and duty ratio on surface characteristics including overcut and machining depth for NaCl, NaNO3 and NaNO3 + NaCl electrolytes. From the experimental investigation, it is observed that the combined effect of lower duty ratio and higher frequency generates the best array of micro circular impressions using the mixed electrolyte of NaNO3 + NaCl with mean radial overcut of 23.31 µm and mean machining depth of 14.1 µm.

Electrochemical Micromachining of Linear Micropattern on Stainless Steel Surface

“…Maskless EMM is used to create the microtexturesusing various wave shapes [11]. Micro circular impressions are made using maskless EMM [12]. In this study, an advanced method of EMM called maskless EMM, is developed to generate highquality linear micropatterns and improve dimensional regularity in linear micropattern.…”

Evaluation of surface integrity in electrochemical micromachining of A286 super alloy

“…ECMM process parameters like voltage, current, duty cycle, electrolyte concentration, feed, inter electrode gap (IEG) and temperature play a significant role in the improvement of surface finish, accuracy and precision [24,25]. Sodium nitrate, ethylene glycol, polyethylene glycol and their combination of electrolytes possess inherent capability to produce micro holes, array patterns in different types of materials that includes SS304, 316L, copper, titanium, nimonic, nitinol and cobalt based alloys with good accuracy and surface finish [26][27][28][29][30][31][32][33]. The usage of passivating, non passivating electrolyte and combination of electrolytes that is composite type electrolyte resulted in improvement of microhole precision in ECMM process [34].…”