| The surface texture in the engine piston, piston ring of a car can store oil, improve the lubrication properties of the friction pair surface, reduce wear, and improve energy's utilization. Electrochemical Machining (ECM) to produce a dimple of pits array in the surface of some friction pair has been a hot spot in national research.Electrochemical machining (ECM) is a course of the anodic electrochemical dissolution of metallic materials in an electrolytic medium utilizing the electrochemical reaction. Due to the tiny size of metal ion, ECM shows a tremendous potential in the micro-manufacturing field, and much attention has been paid on it.This paper focus on micro ECM process of micro-hole in metal thin sheets, the following work has been done:(1)The method of the cathode mask of electrochemical machining is described to produce micro-pits array in the friction pair surface, the analysis of the electric field in the experiment process has been done by using the software of ANSYS.(2)The jig has been designed for generating micro-pits in the surface of piston segments by Electrochemical Micromachining (EMM), and the effects of processing parameters, such as thickness of cathode mask and applied voltage, on the morphology of micro-pits was investigated.(3)The jig has been designed for generating regular pits array in a certain range of the piston cylinder surface by EMM, and the pilot study was conducted. (4)An electrochemical machining method with a mask onto the cathode is employed to produce the micro-pits array. The mathematical model of the enclosed area between the cathode and anode was established to analysis the electric field by using the ANSYS.(5)The effects of thickness of the cathode film, the processing voltage, and the cathode- anode gap on the profile of micro-pits were investigated in the experiment.
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