Yongbin Zeng

Fabrication of Metal Microtool Applying Wire Electrochemical Machining

Metal microtools with various shapes can be used for micromachining technologies due to their specific characteristics. Wire electrochemical machining (wire ECM) shows high potential to produce complex microstructures with repetitive usage of wire electrode and absence of thermal effects. This study presented an investigation of feasibility on fabricating metal microtool with various shapes using microwire ECM process. The experiments were conducted under a condition of ø300 μm tungsten rod as anodic specimen, ø20 μm tungsten wire as cathode, KOH as electrolytic solution, and ultrashort pulsed current as power supply. Effects of pulse-on time, applied voltage, wire feeding rate, and solution concentration on overcut and machining stability were evaluated in order to obtain optimal process parameters. Microtools with various shapes were fabricated thereafter with the optimal condition. The results reveal that the presented approach is capable of producing microtools with complex shapes effectively.

Note: Electrochemical etching of cylindrical nanoprobes using a vibrating electrolyte

An electrochemical etching process using a vibrating electrolyte of potassium hydroxide to prepare tungsten cylindrical nanotips is developed. The vibrating electrolyte eases the effects of a diffusion layer and extends the etching area, which aid in the production of cylindrical nanotips. Larger amplitudes and a vibration frequency of 35 Hz are recommended for producing cylindrical nanotips. Nanotips with a tip radius of approximately 43 nm and a conical angle of arctan 0.0216 are obtained.

Analysis and Reduction of Stray-Current Attack in Reciprocated Traveling Wire Electrochemical Machining:

Traveling wire electrochemical machining is a promising approach for the fabrication of various metal parts. However, the stray-current attack deteriorates the surface quality while it is employed to cut thick workpiece as a normal pulse or DC is used. In this paper, the characteristics of the stray-current attack in reciprocated traveling wire electrochemical machining are firstly identified, and special insulating methods are proposed to reduce the effect of the stray-current. The model of electric field is built. Both the simulation and the experimental results illustrate that the stray-current attack can be reduced significantly by the proposed insulating methods. Finally, structures with fine surface quality on stainless steel 304 with thickness of 20 mm were successfully produced.

Distribution Manner of Compaction Circular Cylinders in Through-Active-Mask Electrochemical Machining

Electrochemical machining is widely used in the processing of difficult-to-machine metal materials. And through-mask electrochemical machining is a very important technology in the processing array structure of difficult-to-cut metal materials. Traditional through-mask electrochemical machining always uses a photoresist as the mask. The production process of a mask is complicated, and the mask cannot be reused. In this paper, through-active-mask electrochemical machining to process array structure in difficult-to-machine metal materials was investigated. Compared with traditional electrochemical machining masks, a copper-clad laminate is used to make the mask by mechanical machining in through-active-mask electrochemical machining. Also, the mask does not stick together with the workpiece but covers the workpiece by mechanical compaction, so the mask can be reused. In order to ensure the mask is in close contact with the workpiece, we need to arrange many compaction circular cylinders within the flow channel. The influences on electrolyte flow of compaction circular cylinders were investigated. The distribution of the compaction circular cylinders affects the electrolyte flow state, thereby affecting the processing. By analyzing the electrolyte flow state for the different distributions of compaction circular cylinders, one can find the best distribution of compaction circular cylinders for the required processing.

Fabrication of a high-aspect-ratio sub-micron tool using a cathode coated with stretched-out insulating layers.

This paper describes a method for preparing a high-aspect-ratio sub-micron tool using a cathode coated with stretched-out insulating layers and a straight reciprocating motion applied at the anode via the liquid membrane electrochemical machining (ECM). Simulation results indicate that the application of a cathode coated with stretched-out insulating layers is beneficial for the localization of ECM. Moreover, a mathematical model was derived to estimate the final average diameter of the fabricated tools. Experiments were conducted to verify the versatility and feasibility of the proposed method and its mathematical model. It was observed that the calculated and the experimental results are in good agreement with each other. A sub-micron tool with an average diameter 140.8 nm and an aspect ratio up to 50 was fabricated using the proposed method.

Note: Buoyant-force assisted liquid membrane electrochemical etching for nano-tip preparation

A liquid membrane electrochemical etching process for preparing nano-tips is proposed by the introduction of buoyant force to the lower tip, in which the lower portion of the anodic wire is immersed into a floating layer. A mathematical model of this method is derived. Both calculation and experimental results demonstrate that the introduction of buoyant force can significantly decrease the tip radius. The lubricating oil and deionized water floating layers were tested for the processing of nano-tips. Further, high-aspect-ratio nano-electrodes were prepared by applying a relative vertical movement to the anodic wire.