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Multi-Ion-Based Modelling and Experimental Investigations on Consistent and High-Throughput Generation of a Micro

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  • 1Department of Mechanical Engineering, Katholieke Universiteit Leuven, Oude Markt 13, 3000 Leuven, Belgium.

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Mask electrolyte jet machining (MEJM) enables controllable, high-throughput micro-texturing on large scales. This study introduces a duckbill nozzle for batch micro-structuring, demonstrating consistent fabrication of micro-cavity arrays on stainless steel.

Keywords:
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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Processes
  • Surface Engineering

Background:

  • Existing large-scale micro-texturing methods face challenges in controllability and consistency.
  • Electrochemical machining (ECM) techniques offer potential but require optimization for throughput and precision.
  • Mask electrolyte jet machining (MEJM) emerges as a hybrid approach combining advantages of masked-ECM and jet-ECM.

Purpose of the Study:

  • To enhance the capability of MEJM for batch micro-structuring using a novel duckbill jet nozzle.
  • To investigate the influence of machining parameters on micro-cavity formation.
  • To validate the controllability and consistency of MEJM for fabricating micro-texture arrays.

Main Methods:

  • Development of a hybrid MEJM system incorporating a duckbill jet nozzle.
  • Construction of a multiphysics model to simulate ion distribution, current density, and cavity evolution.
  • Experimental fabrication of micro-cavity arrays on 304 stainless steel, varying machining voltage and nozzle speed.

Main Results:

  • Successful generation of 35x35 micro-cavity arrays with controlled dimensions (diameter: 11.73-24.92 μm, depth: 7.24-15.86 μm).
  • Demonstrated influence of machining voltage and nozzle moving speed on micro-cavity characteristics.
  • Validation of the multiphysics model's predictions against experimental outcomes.

Conclusions:

  • The enhanced MEJM with a duckbill nozzle provides a controllable and consistent method for large-scale micro-texturing.
  • This technique offers improved dimensional tolerance consistency compared to traditional methods.
  • The developed approach is suitable for high-throughput batch micro-structuring of materials like 304 stainless steel.