Hybrid Electrochemical Additive and Subtractive Manufacturing (HEASM) based on Simultaneous Mask Electrochemical Deposition and Dissolution

Abstract This paper proposed a method for hybrid electrochemical additive and subtractive manufacturing (HEASM) to fabricate microstructures with high dimensional accuracy and good surface quality. Electrochemical additive manufacturing is achieved by applying positive pulses between the electrodes and then negative pulses are subsequently applied to achieve electrochemical finishing of the shape and surface. In this study, the formation of irregular surface defects was investigated, and a verification experiment was carried out. The inter-electrode pulse waveform and machining process were observed to characterize the electrochemical deposition and dissolution machining. The effects of pure electrodeposition, HEASM, and excessive electrolysis on the surface morphology were compared experimentally. The results indicate that HEASM can reduce the surface roughness by 45.5% but excessive electrolysis can cause a collapse of edge regions. Finally, Taguchi optimization experiments were carried out, and an optimized parameter combination for HEASM was obtained. A microstructure manufactured with an optimized pulse number ratio 0.6 × 10 −2 , peak current ratio 0.5, and pulse width ratio 1.0 had the best surface morphology and dimensional accuracy. And its surface roughness and height were 0.343 μm and 33.563 μm, respectively.