Hard Particle Mask Electrochemical Machining of Micro-Textures

The efficient and cost-effective preparation of masks has always been a challenging issue in mask-based electrochemical machining. In this paper, an electrochemical machining process of micro-textures is proposed using hard particle masks such as titanium and zirconia particles. Numerical simulations were conducted to analyze the formation mechanisms of micro-protrusion structures with insulating and conductive hard particle masks, followed by experimental verification of the process. The results indicate that when the hard particles are electrically insulating, metal material preferentially dissolves at the center of the particle gap, and the dissolution then expands over time in depth and towards the particle contact points. Conversely, using the conductive particles as the masks, such as titanium particles, dissolution initially occurs in a ring region centered at the contact point between the hard particle and the anode, with a radius approximately one-quarter of the chosen particle's diameter (200 μm), and then continues to expand outward.