Generation of square micropattern using electrochemical micromachining

Surface microtexturing accomplishes a substantial role in enhancing the interfacial functional performance of machine-driven components. For producing good-quality square micropatterns, maskless electrochemical micromachining (EMM) is a viable option. Maskless EMM is employed for producing micropatterns, wherein the workpiece remains close by interaction with the mask tightly enclosed to the coated tool surface, and the electrolysis of job involves in the enclosed cell. The special micropatterning setup is developed to produce the good quality square micropatterns including micropatterning cell, pulsed electrical unit and perpendicular cross flow electrolyte system. The developed flow method on the job surface in this unit produces better good quality micropatterns. A reused textured tool and developed flow method is applied in maskless EMM in an enclosed unit, which eradicates the sludges and fabricate micropatterns with higher depth. This unique method is an efficient approach for improving the dimensional accuracy of micropatterns. The influences of input criteria, viz. voltage, duty ratio and frequency are studied on surface roughness, current efficiency, length overcut, and textured depth using this technique. The experimental outcomes show that the best parametric combination, viz. 30% duty ratio, 5 kHz frequency and 8 V voltage, enhances the micropatterned quality. A study has been approached based on micrographs for attaining the best input criteria combination.