Ultrasonic energy field-assisted layer milling using side-wall-insulated cathode

IF 2.6 4区化学 Q3 ELECTROCHEMISTRY Journal of Solid State Electrochemistry Pub Date : 2025-03-04 DOI:10.1007/s10008-025-06237-w

Minghuan Wang, Rujun Tian, Shuangqing Guan, Ruiyong Zhang, Hang Zhou, Shixin Zhu, Chunyan Yao, Ruochong Zhang, Xuefeng Xu

{"title":"Ultrasonic energy field-assisted layer milling using side-wall-insulated cathode","authors":"Minghuan Wang, Rujun Tian, Shuangqing Guan, Ruiyong Zhang, Hang Zhou, Shixin Zhu, Chunyan Yao, Ruochong Zhang, Xuefeng Xu","doi":"10.1007/s10008-025-06237-w","DOIUrl":null,"url":null,"abstract":"<div><p>Electrochemical micro-milling (ECMM) is promising in machining micro-parts with the increasing demand for precise and small parts in the industrial field. However, the machining accuracy is always a problem due to the over-corrosion in ECMM. Considering the machining accuracy and the material removal rate, ultrasonic-assisted ECMM using a side wall insulated cathode was proposed in this study. Ultrasonic vibration promotes the discharge of the byproducts and enhances the renewal of electrolyte in the interelectrode and the coating on the cathode, reducing the overcut of the workpiece material. Microgrooves and 3D structures are processed layer by layer, and the cross-sectional profiles and surface roughness are measured by a 3D laser scanning microscope. Firstly, the influences of individual parameters on machining performances were analyzed, and their optimal values were obtained. Then, different milling schemes concerning the layered cathode feeding depth, milling trajectory, and offset were designed to investigate and discover the performances of machined 3D microstructures. Finally, a semi-spherical workpiece with a diameter of 600 µm, surface roughness of 223 nm, a cantilever with a width of 101.6 µm, and an aspect ratio of 8.43 was successfully processed based on the optimized parameters.</p></div>","PeriodicalId":665,"journal":{"name":"Journal of Solid State Electrochemistry","volume":"29 4","pages":"1561 - 1576"},"PeriodicalIF":2.6000,"publicationDate":"2025-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Solid State Electrochemistry","FirstCategoryId":"5","ListUrlMain":"https://link.springer.com/article/10.1007/s10008-025-06237-w","RegionNum":4,"RegionCategory":"化学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"ELECTROCHEMISTRY","Score":null,"Total":0}

引用次数: 0

Abstract

Electrochemical micro-milling (ECMM) is promising in machining micro-parts with the increasing demand for precise and small parts in the industrial field. However, the machining accuracy is always a problem due to the over-corrosion in ECMM. Considering the machining accuracy and the material removal rate, ultrasonic-assisted ECMM using a side wall insulated cathode was proposed in this study. Ultrasonic vibration promotes the discharge of the byproducts and enhances the renewal of electrolyte in the interelectrode and the coating on the cathode, reducing the overcut of the workpiece material. Microgrooves and 3D structures are processed layer by layer, and the cross-sectional profiles and surface roughness are measured by a 3D laser scanning microscope. Firstly, the influences of individual parameters on machining performances were analyzed, and their optimal values were obtained. Then, different milling schemes concerning the layered cathode feeding depth, milling trajectory, and offset were designed to investigate and discover the performances of machined 3D microstructures. Finally, a semi-spherical workpiece with a diameter of 600 µm, surface roughness of 223 nm, a cantilever with a width of 101.6 µm, and an aspect ratio of 8.43 was successfully processed based on the optimized parameters.

查看原文

微信好友朋友圈 QQ好友复制链接

本刊更多论文

随着工业领域对精密小零件的需求不断增加，电化学微铣削（ECMM）在加工微型零件方面前景广阔。然而，由于 ECMM 的过度腐蚀，加工精度始终是个问题。考虑到加工精度和材料去除率，本研究提出了使用侧壁绝缘阴极的超声波辅助 ECMM。超声波振动可促进副产品的放电，加强电极间电解液和阴极涂层的更新，减少工件材料的过切。微槽和三维结构是逐层加工的，其截面轮廓和表面粗糙度由三维激光扫描显微镜测量。首先，分析了各个参数对加工性能的影响，并获得了其最佳值。然后，设计了有关分层阴极进给深度、铣削轨迹和偏移量的不同铣削方案，以研究和发现加工出的三维微结构的性能。最后，根据优化参数成功加工出直径为 600 µm、表面粗糙度为 223 nm、悬臂宽度为 101.6 µm、长宽比为 8.43 的半球形工件。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

求助全文

约1分钟内获得全文去求助

来源期刊

Journal of Solid State Electrochemistry 工程技术-电化学

CiteScore

4.80

自引率

4.00%

发文量

227

审稿时长

4.1 months

期刊介绍： The Journal of Solid State Electrochemistry is devoted to all aspects of solid-state chemistry and solid-state physics in electrochemistry. The Journal of Solid State Electrochemistry publishes papers on all aspects of electrochemistry of solid compounds, including experimental and theoretical, basic and applied work. It equally publishes papers on the thermodynamics and kinetics of electrochemical reactions if at least one actively participating phase is solid. Also of interest are articles on the transport of ions and electrons in solids whenever these processes are relevant to electrochemical reactions and on the use of solid-state electrochemical reactions in the analysis of solids and their surfaces. The journal covers solid-state electrochemistry and focusses on the following fields: mechanisms of solid-state electrochemical reactions, semiconductor electrochemistry, electrochemical batteries, accumulators and fuel cells, electrochemical mineral leaching, galvanic metal plating, electrochemical potential memory devices, solid-state electrochemical sensors, ion and electron transport in solid materials and polymers, electrocatalysis, photoelectrochemistry, corrosion of solid materials, solid-state electroanalysis, electrochemical machining of materials, electrochromism and electrochromic devices, new electrochemical solid-state synthesis. The Journal of Solid State Electrochemistry makes the professional in research and industry aware of this swift progress and its importance for future developments and success in the above-mentioned fields.