Multi-Ion-Based Modelling and Experimental Investigations on Consistent and High-Throughput Generation of a Micro Cavity Array by Mask Electrolyte Jet Machining
The controllability and consistency in the fabrication of micro-textures on large-scale remains a challenge for existing production processes. Mask electrolyte jet machining (MEJM) is an alternative to Jet-ECM for controllable and high-throughput surface microfabrication with more consistency of dim...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-12-01
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| Series: | Micromachines |
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| Online Access: | https://www.mdpi.com/2072-666X/13/12/2165 |
| _version_ | 1827637676967198720 |
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| author | Ming Wu Zhongning Guo Jun Qian Dominiek Reynaerts |
| author_facet | Ming Wu Zhongning Guo Jun Qian Dominiek Reynaerts |
| author_sort | Ming Wu |
| collection | DOAJ |
| description | The controllability and consistency in the fabrication of micro-textures on large-scale remains a challenge for existing production processes. Mask electrolyte jet machining (MEJM) is an alternative to Jet-ECM for controllable and high-throughput surface microfabrication with more consistency of dimensional tolerances. This hybrid configuration combines the high-throughput of masked-ECM and the adjustable flow-field of jet-ECM. In this work, a duckbill jet nozzle was introduced to make MEJM more capable of batch micro-structuring. A multiphysics model was built to simulate the distribution of electrochemical reaction ions, the current density distribution, and the evolution of the shape of the machined cavity. Experimental investigations are presented showing the influence of the machining voltage and nozzle moving speed on the micro cavity. Several <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mn>35</mn><mo>×</mo><mn>35</mn></mrow></semantics></math></inline-formula> micro cavity arrays with a diameter of 11.73–24.92 μm and depth of 7.24–15.86 μm are generated on 304 stainless steel. |
| first_indexed | 2024-03-09T16:05:10Z |
| format | Article |
| id | doaj.art-6de7abe70e104808ab6e73e97d4a0d0c |
| institution | Directory Open Access Journal |
| issn | 2072-666X |
| language | English |
| last_indexed | 2024-03-09T16:05:10Z |
| publishDate | 2022-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Micromachines |
| spelling | doaj.art-6de7abe70e104808ab6e73e97d4a0d0c2023-11-24T16:45:17ZengMDPI AGMicromachines2072-666X2022-12-011312216510.3390/mi13122165Multi-Ion-Based Modelling and Experimental Investigations on Consistent and High-Throughput Generation of a Micro Cavity Array by Mask Electrolyte Jet MachiningMing Wu0Zhongning Guo1Jun Qian2Dominiek Reynaerts3Department of Mechanical Engineering, Katholieke Universiteit Leuven, Oude Markt 13, 3000 Leuven, BelgiumCollege of Mechanical and Electrical Engineering, Guangdong University of Technology, Guangzhou 510006, ChinaDepartment of Mechanical Engineering, Katholieke Universiteit Leuven, Oude Markt 13, 3000 Leuven, BelgiumDepartment of Mechanical Engineering, Katholieke Universiteit Leuven, Oude Markt 13, 3000 Leuven, BelgiumThe controllability and consistency in the fabrication of micro-textures on large-scale remains a challenge for existing production processes. Mask electrolyte jet machining (MEJM) is an alternative to Jet-ECM for controllable and high-throughput surface microfabrication with more consistency of dimensional tolerances. This hybrid configuration combines the high-throughput of masked-ECM and the adjustable flow-field of jet-ECM. In this work, a duckbill jet nozzle was introduced to make MEJM more capable of batch micro-structuring. A multiphysics model was built to simulate the distribution of electrochemical reaction ions, the current density distribution, and the evolution of the shape of the machined cavity. Experimental investigations are presented showing the influence of the machining voltage and nozzle moving speed on the micro cavity. Several <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mn>35</mn><mo>×</mo><mn>35</mn></mrow></semantics></math></inline-formula> micro cavity arrays with a diameter of 11.73–24.92 μm and depth of 7.24–15.86 μm are generated on 304 stainless steel.https://www.mdpi.com/2072-666X/13/12/2165micro surface structuresmask electrolyte jet machiningelectrochemical micro machining |
| spellingShingle | Ming Wu Zhongning Guo Jun Qian Dominiek Reynaerts Multi-Ion-Based Modelling and Experimental Investigations on Consistent and High-Throughput Generation of a Micro Cavity Array by Mask Electrolyte Jet Machining Micromachines micro surface structures mask electrolyte jet machining electrochemical micro machining |
| title | Multi-Ion-Based Modelling and Experimental Investigations on Consistent and High-Throughput Generation of a Micro Cavity Array by Mask Electrolyte Jet Machining |
| title_full | Multi-Ion-Based Modelling and Experimental Investigations on Consistent and High-Throughput Generation of a Micro Cavity Array by Mask Electrolyte Jet Machining |
| title_fullStr | Multi-Ion-Based Modelling and Experimental Investigations on Consistent and High-Throughput Generation of a Micro Cavity Array by Mask Electrolyte Jet Machining |
| title_full_unstemmed | Multi-Ion-Based Modelling and Experimental Investigations on Consistent and High-Throughput Generation of a Micro Cavity Array by Mask Electrolyte Jet Machining |
| title_short | Multi-Ion-Based Modelling and Experimental Investigations on Consistent and High-Throughput Generation of a Micro Cavity Array by Mask Electrolyte Jet Machining |
| title_sort | multi ion based modelling and experimental investigations on consistent and high throughput generation of a micro cavity array by mask electrolyte jet machining |
| topic | micro surface structures mask electrolyte jet machining electrochemical micro machining |
| url | https://www.mdpi.com/2072-666X/13/12/2165 |
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