Laser and electrochemical machining (LECM) is extensively researched due to its high efficiency and good surface quality. Laser and shaped tube electrochemical machining (Laser-STEM) is a novel hybrid process, in which both the laser beam and electrolyte jet are guided to the machining zone through the inner hole of a specially designed tubular electrode. This process could be utilized to process small holes with a larger depth and a higher controlled precision, compared with the existing LECM processes. In Laser-STEM, the direct laser processing and the enhanced electrochemical machining (ECM) rate allow the high-efficiency material removal. ECM that is synchronously occurred in the side gap guarantees the high surface quality of the processed small holes. Through the total internal reflection of the laser beam in the inner hole of the tubular electrode, the laser energy is transmitted to the machining zone in high efficiency, and the laser energy has been confined in the inner hole exit area. Theoretical and experimental results showed that the electric current density in the machining zone for ECM could be increased by the assistance of a laser, which enhances the material removal rate of ECM. With the self-developed experimental setup, microcavities with a depth of 2 mm and small holes with a depth of 5 mm have been fabricated. A comparison of the effects of various machining parameters shows that the machining precision and material removal rate were improved by 60.7% and 122.7%, respectively. Both the machining precision and the material removal rate could be increased by using higher laser power. The mechanisms of machining precision improvement by adopting laser to STEM were explored, considering the generation of the passivating layer in the machining zone. Laser-STEM was also adopted to fabricating three-dimensional structures such as groove and channel.

Theoretical and experimental study on hybrid laser and shaped tube electrochemical machining (Laser-STEM) process

The requirement of deep hole drilling has tremendously increased in recent years and it extensively found applications in automobile fuel injectors, biomedical implants, aerospace landing gears, et...

Recent research progress in deep hole drilling process: a review

Cathodic discharge plasma in electrochemical jet machining: Phenomena, mechanism and characteristics

Tooling aspects of micro electrochemical machining (ECM) technology: Design, functionality, and fabrication routes

In this study, laser-assisted plasma electrolytic oxidation (Laser/PEO) coating was prepared on AZ31B magnesium alloy for corrosion protection, due to insufficient corrosion protection caused by the inherent defects, cracks and poor quality of PEO coatings. The plasma discharge evolution, morphological characteristics, elemental composition during coating growth were characterized by high-speed camera, SEM, EDX, XRD and XPS, respectively. Meanwhile, Mott Schottky (M-S) curves, potentiodynamic polarization (PDP) curves and electrochemical impedance spectroscopy (EIS) tests characterized the oxygen vacancy defects and corrosion resistance of the coatings. The results demonstrated that laser-assisted irradiation not only induced plasma discharge on the anode surface, but also limited the plasma discharge size in the post-processing stage, which significantly increased the proportion of corrosion-resistant phase Mg2SiO4 (the proportion of Mg2SiO4 increased from 23.70% to 39.22%), thickness and density in the coating, and obviously reduced the oxygen vacancy defects and microcracks in the coating. As a result, the corrosion resistance of the Laser/PEO coating (9.29(±0.76)×10−7 A·cm−2) was further enhanced in comparation with the PEO coating (3.06(±0.19)×10−6 A·cm−2). 

The growth mechanism and corrosion resistance of laser-assisted plasma electrolytic oxidation (PEO) composite coating on AZ31B magnesium alloy

The synchronized laser and shaped tube electrochemical machining (Laser-STEM), a hybrid machining process that combined the advantages of electrochemical machining (ECM) and laser beam machining (LBM), has been proposed and studied. The mechanisms of Laser-STEM were studied theoretically and experimentally. Mathematical model has been developed to study the effects of laser-induced thermal effects on the electrochemical dissolution rate. The influences of electrolyte concentration and laser power on the laser attenuation coefficient have been studied. Results showed that the side gap could be decreased by 62.7% and the feeding rate could be raised by 108% when utilizing Laser-STEM with a proper laser power for drilling small holes, compared with that without laser assistance. Moreover, the performance of Laser-STEM has been investigated, in terms of laser power and pulsed voltage. Experimental results showed that the machining efficiency increased with higher laser power, pulse voltage, and feeding rate, and the precision could be improved with the higher laser power and feeding rate and a smaller pulsed voltage. Finally, small holes with a diameter of 1.25 mm and free of recast layer have been fabricated on the aluminum alloy workpiece of 5 mm in thickness.

Fabrication of deep and small holes by synchronized laser and shaped tube electrochemical machining (Laser-STEM) hybrid process

The invention discloses a laser-electrolysis composite rotary machining device. A rotary electrode unit and a rotary drive unit are arranged on an installation base; the rotary electrode unit comprises a hollow main shaft, a rotary sealing seat forming rotary fit with the upper part of the hollow main shaft, and a tubular electrode fixedly connected with the lower part of the hollow main shaft; and the tubular electrode is electrically connected with a power supply unit. The interiors of the hollow main shaft and the tubular electrode are communicated to form a medium channel. The rotary driveunit comprises a motor, and the motor drives the hollow main shaft to rotate through a transmission mechanism. The rotary sealing seat is connected with an electrolysis unit through an electrolyte inrushing pipeline and used for inputting an electrolyte to the medium channel. A laser unit used for emitting a laser beam into the medium channel is arranged at the upper end of the hollow main shaft.According to the laser-electrolysis composite rotary machining device, a laser-electrolysis composite rotary machining technology is adopted, and efficient coupling is carried out on the totally-reflected laser beam and the electrolyte, so that laser-electrolysis composite machining for pores with large depth-diameter ratios is realized, and the removal speed and the machining depth for a material are increased.

Laser-electrolysis composite rotary machining device

The invention discloses a multi-electrode synchronous laser and electrolysis composite processing device. The multi-electrode synchronous laser and electrolysis composite processing device comprises alaser beam and a plurality of tube electrodes, wherein the tube electrodes are arranged in electrolyte of an electrolyte distributing cavity side by side at intervals. The incident laser beam is evenly split into a plurality of beams by at least one proportional spectroscope and a reflector. The split laser beam passes through a focusing position adjusting device, is aligned at and enters upper ports of the corresponding tube electrodes, and acts on processing areas at the lower ends of the tube electrodes. According to the multi-electrode synchronous laser and electrolysis composite processing device, a proportional light splitting system composed of the proportional spectroscope(s) and the reflector is adopted, so that approximately uniform distribution of laser energy in each discretely distributed tube electrode is realized. Uniform distribution of the electrolyte in each discretely distributed tube electrode is realized by using the electrolyte distributing cavity, alignment andcoupling of the split laser beam and the tube electrodes are realized through the designed focusing position adjusting device, and the laser and electrolytic composite processing efficiency is greatlyimproved.

Multi-electrode synchronous laser and electrolysis composite processing device

This paper proposed a new high-surface-quality and high-precision small hole processing technique by using laser and electrochemical hybrid machining (LECM) based on internal total reflection (ITR). During LECM via ITR the laser beam could be transferred to the large depth with a small attenuation machining area as the tube electrode feeds into the inner workpiece. The mechanisms of LECM via ITR has been clarified. The ITR through the tube electrode is also studied, in mathematical and simulation manner. Additionally, with the developed experimental setup, the feasibility of LECM via ITR has been proved. Experimental results demonstrated that the side gap could be decreased by laser assistance in LECM, and the side gap has been decreased by 25%.

Laser and electrochemical hybrid machining (LECM) based on internal total reflection effect

Development of Laser and Electrochemical Machining Based on Internal Total Reflection

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