Micro-dimple array structure is a widely accepted approach for friction reduction between mechanicalcomponents. At present, there are many methods to form micro-dimple arrays on metal surface, but howto form high-quality and low-cost micro-dimple arrays is still a challenge. Ultrasonic assistedelectrochemical micromachining (UAEMM) is considered to be a promising machining technology dueto its advantages of high machining efficiency, high machining accuracy and no limitation of mechanicalproperties of work-piece materials. In this paper, the UAEMM technology is used to process the microdimple array structure on the metal surface. The experimental results show that the voltage is helpful toimprove the machining depth, but too much voltage will also reduce the machining accuracy, and theoptimal choice of voltage parameter is 2-3V voltage. Compared with DC power, pulse power used inUAEMM process can achieve better machining performance. The machining accuracy and surfacequality can be further improved by modulating the synchronous relationship between ultrasonic andpulse. Finally, a better micro pit array structure was prepared according to the optimized processparameters, and its friction performance was tested. The results show that under the same conditions, thesurface wear of micro-dimple array surface is less than one third of that of the plane surface.
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