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针对难加工金属材料表面阵列非贯穿型微沟槽的高效高质量加工难题,提出一种场域离散脉冲电解加工方法,所加工沟槽具有表面质量好、尺寸微小、槽数多、沟槽前后非贯穿的特点。使用绝缘栅栏隔板作为活动掩模板对各微沟槽加工区进行离散,同时遮蔽非加工区,从而实现流场隔离和非加工区电场屏蔽等效果,有效提高沟槽的加工稳定性、精度和一致性。通过设计专用夹具,对影响加工精度的关键因素进行了单因素工艺实验研究,并利用Comsol Multiphysics软件对电解加工的流场和电场进行了仿真分析。仿真和试验结果显示:场域离散加工方法的流场和电场都比传统的掩膜电解加工、电解转印加工好。成功地在1min内加工出9条宽538.76μm,深25.78μm,过切量为19.38μm的阵列微沟槽,证实了该方法的有效性。采用短加工时间、低脉冲电压幅值、高脉冲频率、小脉冲占空比等工艺参数,有利于提高沟槽的加工精度。通过场域离散电解加工技术,可以实现对非贯穿型微沟槽的高效率、高质量、低成本加工。 相似文献
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针对微细电解加工表面微织构加工精度较差等问题,提出超声振动辅助模板电解加工方法。制备具有通孔结构的聚二甲基硅氧烷(PDMS)绝缘模板,设计制作超声振动变幅杆结构;进行超声振动辅助模板电解加工仿真分析,开展微凹坑加工试验研究。在加工电压为12 V和加工时间为12 s条件下,辅助以纵向超声波振动频率为28 kHz及超声振幅为7μm时有:绝缘模板作用下加工的微凹坑深度为10.4μm,直径为116μm;无绝缘模板作用下加工的微凹坑深度为9.7μm,直径为126μm;无超声振动时绝缘模板作用下加工的微凹坑深度为4.1μm,直径为114μm。 相似文献
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安全滤网阵列网孔的高效、高品质和高适应性加工至今仍面临重大技术挑战。基于此,提出采用激光-电解组合加工技术制备安全滤网阵列网孔结构。介绍了激光-电解组合加工技术的试验加工系统,探究了工艺参数对微孔形貌质量和加工精度的影响规律,并开展了安全滤网阵列网孔的制备。试验结果表明:激光加工路径显著影响微孔出口的形貌,采用同心圆轨迹(外径270μm,内径230μm,线间距2.5μm)能够显著改善微孔出口的圆度;激光功率越大、切割速度越小,微孔直径及其热影响区均越来越大;NaNO3-乙二醇溶液作为电解抛光液能够在加工表面形成扩散层发生电解抛光,将激光加工产生的喷溅物和毛刺等缺陷去除;基于优化工艺参数,加工出253个直径0.31 mm的阵列网孔结构,出入口直径方差仅为2.02和1.71,展示出较高的尺寸一致性。激光-电解组合加工技术在薄壁件上高效、高品质制备阵列网孔结构方面具有很强工艺能力和发展潜力。 相似文献
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采用掩膜电解加工单个微孔的方式研究加工参数对凹坑形貌的影响,该方法具有操作简易以及工件无内应力等优点。采用COMSOL软件对加工间隙的电场进行仿真分析,研究了掩膜电解加工间隙对阳极表面电流分布的影响。实验中采用光刻技术在阳极工件表面制作尺寸均匀的微孔,孔径500μm,厚度50μm,通过采用不同加工电解液,电解液浓度,加工间隙以及加工电压加工凹坑并研究不同条件对凹坑形貌的影响。实验结果表明:随电解液浓度、加工电压的增加凹坑的孔径和孔深都出现不同程度增加;随加工间隙的增大孔径增大程度减小,孔深没有一致规律;NaCl溶液加工的凹坑比NaNO_3出现杂散腐蚀严重。 相似文献
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为改善铝合金的摩擦学性能,运用有限元方法对单一方形凹坑、条形凹槽、方形凹坑和条形凹槽组合3种不同形貌织构摩擦副间润滑油膜承载能力进行仿真分析,并探究不同织构尺寸对油膜承载能力的影响。仿真结果表明:方形凹坑和条形凹槽组合织构润滑油膜承载能力最佳。采用脉冲Nd:YAG激光器在铝合金试件表面加工出具有规则形貌的方形凹坑和条形凹槽组合的织构阵列,借助CFT-I型高速往复摩擦磨损试验机进行摩擦试验,研究织构几何尺寸对摩擦副接触面间摩擦学性能的影响规律,并利用超景深显微系统对试件磨损表面的形貌进行观测。试验结果表明:组合织构化表面的平均摩擦因数与无织构表面相比明显减小,且波动幅度较小;当织构尺寸为80μm时,织构表面的摩擦因数最小,且试验得到的基体表面磨痕深度随织构尺寸的变化规律,与仿真计算得到的润滑油膜升力系数的变化规律相吻合,为微织构参数设计提供了一定的理论依据。 相似文献
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Generating micro-dimples array on the hard chrome-coated surface by modified through mask electrochemical micromachining 总被引:1,自引:0,他引:1
Shuangqing Qian Di Zhu Ningsong Qu Hansong Li Dongsheng Yan 《The International Journal of Advanced Manufacturing Technology》2010,47(9-12):1121-1127
It has been recently identified that micro-dimples can act as fluid reservoirs and promote the retention of a lubricating film to reduce friction between mechanical components. Various techniques are employed to produce micro-dimples on the surface of friction pair. In this study, a modified through mask electrochemical micromachining (TMEMM), in which the insulation layer was directly attached to the cathode, was developed to produce micro-dimples on the hard chrome-coated surface. By controlling machining parameters, micro-dimples array, with hundreds of micrometers in diameter and several micrometers in depth, were produced. Compared with the traditional TMEMM, the modified method can both reduce cost and improve machining efficiency. Friction experiments show that the friction coefficient of the surface with appropriate micro-dimples array is obviously lower than that with nondimples. 相似文献
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为改善钛合金疏水性能,获得较高的接触角,使用掩膜电解技术对钛合金进行了凹坑阵列表面微织构的加工。首先,建立微坑阵列掩膜电解加工的数学模型并进行多物理场耦合仿真;其次,分析掩膜电解加工参数对微坑阵列的作用,并借助润湿理论模型获得微坑阵列的固-液接触面积比;最后,以该面积比为因变量,以电解质质量分数、电解电压和掩膜尺寸为自变量,进行正交试验仿真和极差分析,获得最佳工艺参数组合。与仿真预测值相比,微坑阵列单元体直径、间距、深度、固-液接触面积比和表面接触角的测量值误差均小于8%,从而表明该方法在未经低表面能材料修饰的情况下,成功制备了接触角约为140°的微坑阵列。 相似文献
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Ningsong Qu Xiaolei Chen Hansong Li Di Zhu 《The International Journal of Advanced Manufacturing Technology》2014,72(1-4):487-494
Surface texture has played a fundamental role in the development of many advanced fields. Through mask electrochemical micromachining (TMEMM) is a feasible alternative for fabricating surface textures. In this paper, polydimethylsiloxane (PDMS) is firstly employed as a mask in TMEMM due to its chemical resistance, low cost, flexibility and high moulding capability. A simple method for fabricating PDMS micro through-holes is proposed. A vacuum-aided process was introduced to fill a PDMS gel into an SU-8 mould, and the PDMS gel was solidified in an oven. Then, the cured PDMS micro through-holes were peeled off of the SU-8 mould. PDMS micro holes with a minimum diameter of 50 μm and a thickness of 200 μm were obtained. Furthermore, the PDMS micro through-holes were then used as a mask to prepare a micro dimple array by TMEMM. Experiments were conducted to verify the feasibility of the proposed approach, and the effect of applied voltage and machining time on the diameter and depth of the micro dimple was investigated. Finally, an array of micro dimples 109 μm in diameter and 9.7 μm deep was successfully fabricated by using PDMS. 相似文献
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Jing Sun Wei Cheng Jin-Long Song Yao Lu Yan-Kui Sun Liu Huang Xin Liu Zhu-Ji Jin Claire J-Carmalt Ivan P-Parkin 《机械工程学报(英文版)》2018,(4)
Surfaces with controllable micro structures are significant in fundamental development of superhydrophobicity. However,preparation of superhydrophobic surfaces with array structures on metal substrates is not effective using existing methods. A new method was presented to fabricate super-hydrophobic post arrays on aluminum(Al) substrates using mask electrochemical machining and fluoridation. Electrochemical etching was first applied on Al plates with pre-prepared photoresist arrays to make the post array structures. Surface modification was subsequently applied to reduce the surface energy, followed by interaction with water to realize superhydrophobicity. Simulation and experimental verification were conducted to investigate how machining parameters affect the array structures. Analysis of the water contact angle was implemented to explore the relationship between wettability and micro structures.The results indicate that superhydrophobic surfaces with controllable post structures can be fabricated through this proposed method, producing surfaces with high water static contact angles. 相似文献
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Donglin Li Di Zhu Hansong Li 《The International Journal of Advanced Manufacturing Technology》2011,55(1-4):189-194
Electrochemical micromachining (EMM) has been gaining popularity as an alternative method to fabricate microstructure. A method of EMM is proposed to produce microhole array or micro-dimple array, in which a patterned inert metal mask (platinum plate) is closely attached to workpiece (anode), not bonded to the anode. When voltage is applied across the anode and the cathode over which electrolyte flows at a high speed, the patterns in the mask are transferred to the anode, and microstructures are produced. A mathematical model to describe the actual machining process is established. By considering the effect of nonlinear electrolyte, the parametric finite element method is adopted to simulate and numerically analyze the erosion process. Some experiments are performed to verify the proposed model. 相似文献