Enhanced Metal Surface Processing Through the No-Stray-Corrosion Controllable Electrolyte DistributionElectrochemical Machining Method Utilizing a Water-Absorbent Porous Ball
The Electrochemical Machining (ECM) method is one of the most widely used processing methods in metal surface processing, due to its unique advantages. However, the electrolyte in ECM causes stray corrosion on the workpiece. To overcome these shortcomings, we have developed a no-stray-corrosion ECM...
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MDPI AG
2025-07-01
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| Series: | Micromachines |
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| Online Access: | https://www.mdpi.com/2072-666X/16/7/822 |
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| author | Jiankang Wang Qiyuan Cao Ye Chen Wataru Natsu Jianshu Cao |
| author_facet | Jiankang Wang Qiyuan Cao Ye Chen Wataru Natsu Jianshu Cao |
| author_sort | Jiankang Wang |
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| description | The Electrochemical Machining (ECM) method is one of the most widely used processing methods in metal surface processing, due to its unique advantages. However, the electrolyte in ECM causes stray corrosion on the workpiece. To overcome these shortcomings, we have developed a no-stray-corrosion ECM method called the controllable electrolyte distribution ECM (CED-ECM) method. However, its practical application in metal surface processing remains largely unexplored. In this study, to improve the CED-ECM method, we delved deeper into the aforementioned aspects by simulating the actual ECM process using COMSOL Multiphysics and rigorously validating the simulation results through practical experimental observations. Then, our efforts led to the application of the CED-ECM method to metal surface processing for the SUS304 workpiece, producing noteworthy results that manifest in diverse cross-sectional profiles on the processed surfaces. This research demonstrates a validated simulation framework for the CED-ECM process and establishes a method for creating user-defined surface profiles by controlling pass intervals, enabling new applications in surface texturing. |
| format | Article |
| id | doaj-art-00db3ac8e30c4bb99840a96db94e6ff0 |
| institution | Matheson Library |
| issn | 2072-666X |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Micromachines |
| spelling | doaj-art-00db3ac8e30c4bb99840a96db94e6ff02025-07-25T13:30:40ZengMDPI AGMicromachines2072-666X2025-07-0116782210.3390/mi16070822Enhanced Metal Surface Processing Through the No-Stray-Corrosion Controllable Electrolyte DistributionElectrochemical Machining Method Utilizing a Water-Absorbent Porous BallJiankang Wang0Qiyuan Cao1Ye Chen2Wataru Natsu3Jianshu Cao4School of Engineers, Beijing Institute of Petrochemical Technology, Qingyuan North Road No. 19, Daxing District, Beijing 102617, ChinaAcademy of Artificial Intelligence, Beijing Institute of Petrochemical Technology, Qingyuan North Road No. 19, Daxing District, Beijing 102617, ChinaGeneral Technology Group Machine Tool Engineering Research Institute, Wangjing Road No. 4, Chaoyang District, Beijing 100102, ChinaDepartment of Mechanical Systems Engineering, Tokyo University of Agriculture and Technology, 2-24-16 Nakacho, Koganei City, Tokyo 184-8588, JapanSchool of Engineers, Beijing Institute of Petrochemical Technology, Qingyuan North Road No. 19, Daxing District, Beijing 102617, ChinaThe Electrochemical Machining (ECM) method is one of the most widely used processing methods in metal surface processing, due to its unique advantages. However, the electrolyte in ECM causes stray corrosion on the workpiece. To overcome these shortcomings, we have developed a no-stray-corrosion ECM method called the controllable electrolyte distribution ECM (CED-ECM) method. However, its practical application in metal surface processing remains largely unexplored. In this study, to improve the CED-ECM method, we delved deeper into the aforementioned aspects by simulating the actual ECM process using COMSOL Multiphysics and rigorously validating the simulation results through practical experimental observations. Then, our efforts led to the application of the CED-ECM method to metal surface processing for the SUS304 workpiece, producing noteworthy results that manifest in diverse cross-sectional profiles on the processed surfaces. This research demonstrates a validated simulation framework for the CED-ECM process and establishes a method for creating user-defined surface profiles by controlling pass intervals, enabling new applications in surface texturing.https://www.mdpi.com/2072-666X/16/7/822metal surface processingno-stray-corrosion ECM methodcontrollable electrolyte distribution ECM (CED-ECM)water-absorbent porous ballmodeling and simulation |
| spellingShingle | Jiankang Wang Qiyuan Cao Ye Chen Wataru Natsu Jianshu Cao Enhanced Metal Surface Processing Through the No-Stray-Corrosion Controllable Electrolyte DistributionElectrochemical Machining Method Utilizing a Water-Absorbent Porous Ball Micromachines metal surface processing no-stray-corrosion ECM method controllable electrolyte distribution ECM (CED-ECM) water-absorbent porous ball modeling and simulation |
| title | Enhanced Metal Surface Processing Through the No-Stray-Corrosion Controllable Electrolyte DistributionElectrochemical Machining Method Utilizing a Water-Absorbent Porous Ball |
| title_full | Enhanced Metal Surface Processing Through the No-Stray-Corrosion Controllable Electrolyte DistributionElectrochemical Machining Method Utilizing a Water-Absorbent Porous Ball |
| title_fullStr | Enhanced Metal Surface Processing Through the No-Stray-Corrosion Controllable Electrolyte DistributionElectrochemical Machining Method Utilizing a Water-Absorbent Porous Ball |
| title_full_unstemmed | Enhanced Metal Surface Processing Through the No-Stray-Corrosion Controllable Electrolyte DistributionElectrochemical Machining Method Utilizing a Water-Absorbent Porous Ball |
| title_short | Enhanced Metal Surface Processing Through the No-Stray-Corrosion Controllable Electrolyte DistributionElectrochemical Machining Method Utilizing a Water-Absorbent Porous Ball |
| title_sort | enhanced metal surface processing through the no stray corrosion controllable electrolyte distributionelectrochemical machining method utilizing a water absorbent porous ball |
| topic | metal surface processing no-stray-corrosion ECM method controllable electrolyte distribution ECM (CED-ECM) water-absorbent porous ball modeling and simulation |
| url | https://www.mdpi.com/2072-666X/16/7/822 |
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