Micro textures are widely used to achieve specific functions including friction performance, heat dispersion, and surface superhydrophobic. Improving the integrity of surface texturing is helpful to achieve the requested function of products. Electrochemical machining (ECM) is a promising approach to manufacture such textures on the metallic workpiece surface. However, dissolution of the workpiece through the patterned cathode always leads to an undercutting in workpiece in ECM process. This undercutting enlarges the pattern shape, thereby decreasing the machining accuracy. Li et al. presented an electrochemical micro machining by using side-insulated electrode to improve the ECM accuracy. Chen et al. reported that a thick mask was introduced to prevent escape of the oxygen bubbles from the micro-dimples. Oxygen bubbles accumulating at the micro-dimple edges might protect the edges from etching, thereby reducing undercutting and improving machining accuracy. Also, in order to solve the problem of low machining accuracy, it is a good way to limit the existing area of electrolyte. As effective methods of limiting area in ECM, electrolyte jet machining and electrochemical machining with electrolyte suction tool have been proposed. In ECM with suction tool, the electrolyte is circulated in the area between tool end-surface and workpiece by using one pump, and the gap-width can be detected with the pressure of the pump. Because the electrolyte is successfully limited under the tool, the machining accuracy improves and there is no electrolyte scattering.
展开▼
