Investigation and optimization of pulsed electroforming process parameters for thickness distribution of a revolving nickel part

Abstract

The objective of this research is to examine the influence of low frequency pulsed electroforming process parameters, such as current, pulse-on time, pulse-off time, and electrolyte temperature, to obtain good thickness uniformity. For this purpose, a pulsed electroforming system was designed and made. Three level, four-parameter experiments were designed using Taguchi method. The effect of parameters and optimal parameters combination were obtained through signal-to-noise ratio (S/N), analysis of variance (ANOVA) and Pareto ANOVA method. Also the regression analysis was performed to obtain a predictive model. The results demonstrated that current has a dominant effect on thickness distribution and pulse-on time, temperature and pulse-off time affect thickness distribution, respectively. Optimum electroforming process parameters were determined and experimental tests were conducted to verify the optimized parameters. The results showed the effectiveness of the proposed optimization method.

Review—Electroforming Process for Microsystems Fabrication

“…They employed the Taguchi method to determine the optimal parameter combination and assess parameter effects, utilizing techniques such as signal-to-noise ratio (S/ N), analysis of variance (ANOVA), and Pareto ANOVA analysis. 134 If we combine the electroforming process, we can make use of this empirical data in an algorithm to train a model and predict how the process will behave if we change any parameter. It can be used to find out the optimized value of any parameter to minimize the cost of production as well as improve the quality of an electroformed component.…”

Investigation and modeling on electroformed micro electrolysis pump using regression analysis

“…In this equation only current density and current efficiency are the variables and the other parameters are constant during a special electroforming process (27). Current density can be affected by an anode-cathode configuration based on the theory of electrostatic field and electro deposition (20). In a two-dimensional region between anode and cathode, the electric potential can be expressed by the Laplace equation ( ∆ 2 V = 0 ) (26,28,29).…”

“…In this process, electro-deposition used to make an independent metal part with free form configuration (14, 19). During the electroforming process positive metal ions deposit on mandrel surface with negative pole and after reaching sufficient thickness, the mandrel would eliminated (14,20). A shell metal part with free form would be the output of electroforming process (21,22).…”

Electroforming in the Industry 4.0 Era

“…While many of these ideas have yet to mature, Industry 4.0 will affect all manufacturing. Its impact has also been highlighted in manufacturing journals citing crosstechnology innovation involving electrochemical processes [7][8][9][10]. These publications focused on electrochemical deposition as an "additive" forming technique [8][9][10].…”

“…Its impact has also been highlighted in manufacturing journals citing crosstechnology innovation involving electrochemical processes [7][8][9][10]. These publications focused on electrochemical deposition as an "additive" forming technique [8][9][10]. Novel manufacturing techniques have also featured in electrochemical publications citing inkjet printing of fuel cells [11], laser writing of electrocatalysts for textile manufacture [12], as well as algorithms for optimising micro-fabricated structures [13].…”