Multi-Layer Workpieces and Multiple-Wire Electrochemical Micromachining with Horizontal Electrolyte Flushing

Area of Science:

• Materials Science and Engineering
• Manufacturing Technology
• Electrochemistry

Background:

• Multi-wire electrochemical microfabrication (MWECM) offers potential for high-quality array microstructure production.
• Accumulation of electrolytic by-products in multi-layer workpieces limits machining accuracy and industrial application.

Purpose of the Study:

• To enhance mass transfer and improve machining accuracy in multi-layer workpiece electrochemical microfabrication.
• To address limitations caused by electrolytic deposit accumulation in MWECM.

Main Methods:

• Implemented horizontal electrolyte flushing (MWECMF) to promote discharge of electrolytic deposits and electrolyte renewal.
• Utilized flow field simulation to optimize interlayer workpiece spacing.
• Conducted single factor experiments to determine optimal processing parameters (wire feed speed, voltage, frequency, duty cycle).

Main Results:

• Successfully fabricated array microstructures using a two-wire electrode and four-layer workpiece configuration.
• Achieved an overall machining rate of 9.6 µm/s with a feed rate of 1.2 µm/s.
• Demonstrated significant improvement in machining efficiency compared to traditional methods.

Conclusions:

• MWECMF effectively enhances mass transfer and resolves accuracy issues in multi-layer workpiece fabrication.
• The optimized process parameters and configuration lead to substantially improved machining efficiency.
• This method presents a viable solution for industrial-scale manufacturing of array microstructures.