A tool-based hybrid laser-electrochemical micromachining process: Experimental investigations and synergistic effects

Saxena, Krishna Kumar; Qian, Jun; Reynaerts, Dominiek

doi:10.1016/j.ijmachtools.2020.103569

Cited by 55 publications

(31 citation statements)

References 26 publications

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“…Nearly 25% reduction in passivation layer was observed for Ti6Al4V with laser-ECM as compared to the ECM process However, this was not the case with WC and NbC where there was no difference in the oxygen content of the surface with ECM and laser-ECM as observed from EDX analysis. The weakening of oxide layer is also seen up to a specific laser pulse energy (45 µJ, in the reported experimental configuration 13 ). When comparing laser-ECM to ECM for the given experimental parameters, a 6.03%, 7% and 9.5% rise in average volumetric MRR (material removal rate) has been observed for effective laser pulse energies of 10, 36 and 60 μJ, respectively.…”

mentioning

confidence: 58%

“…When comparing laser-ECM to ECM for the given experimental parameters, a 6.03%, 7% and 9.5% rise in average volumetric MRR (material removal rate) has been observed for effective laser pulse energies of 10, 36 and 60 μJ, respectively. The MRR starts to drop with further increase in laser pulse energy beyond 60 μJ 13 .…”

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confidence: 96%

“…The existing studies are conducted on proof-of-concept test stands where the conditions are totally different than those on the actual machine. In light of the above, this work presents real-time on-machine observations during machining with a tool-based hybrid laser-electrochemical micromachining process 13 . A combination of high speed imaging and particle image velocimetry was used to understand by-product generation, bubble generation, and electrolyte flow behavior close to the machining zone.…”

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confidence: 99%

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Real-time on-machine observations close to interelectrode gap in a tool-based hybrid laser-electrochemical micromachining process

Saxena

Chen

Vetrano

et al. 2020

Sci Rep

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A tool-based hybrid laser-electrochemical micromachining process involves concurrent application of two process energies i.e. electrochemical and laser in the same machining zone by means of a hybrid tool which serves as an ECM tool as well as a multimode waveguide. It is a relatively novel process finding applications in defect-free machining of difficult-to-cut materials without affecting their microstructure. In order to understand the physical phenomena occurring during this process, in-situ observations are required. Therefore, in this work, a real time observation was carried out of a novel tool-based hybrid laser electrochemical micromachining process. A combination of high-speed imaging and Large Scale Particle Image Velocimetry (LSPIV) was used to visualize the tool-based hybrid laser-ECM process in real time. It also allowed to carry out experimental investigations on the by-products and bubble generation which have a direct effect on process performance in terms of accuracy and efficiency. The real-time on-machine observations are unique of its kind and they will facilitate the understanding of underlying mechanisms governing this hybrid laser-electrochemical micromachining process. This will ultimately help in improving the quality of parts manufactured. This research is also a step forward towards making these physics-based hybrid processes deterministic by employing high-speed imaging in a closed loop control.

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confidence: 58%

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confidence: 96%

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confidence: 99%

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Real-time on-machine observations close to interelectrode gap in a tool-based hybrid laser-electrochemical micromachining process

Saxena

Chen

Vetrano

et al. 2020

Sci Rep

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“…A wide range of hard yet conductive materials such as bulk metallic glasses [ 4 ], titanium alloys [ 5 ], superalloys [ 6 ], carbide-metals [ 7 , 8 ] can be effectively machined by ECMM. Several configurations of ECMM process such as jet electrochemical machining [ 9 ], scanning micro-electrochemical flow cell based ECMM [ 10 ], wire electrochemical micromachining [ 11 ], a tool-based hybrid laser-ECM [ 12 ] and through-mask electrochemical micro-machining [ 13 ] have been introduced to generate surface microstructures.…”

Section: Introductionmentioning

confidence: 99%

“…In recent years, several ECMM based new processes have been introduced such as Scanning micro-electrochemical flow cell based micromachining which has capability to fabricate micro-dimples and at the same time confining electrolyte to a droplet [ 10 ]. Similarly, a tool-based hybrid laser-electrochemical micromachining process proposed in Reference [ 12 ] which has capability to fabricate hierarchical microcavities in single-step.…”

Section: Introductionmentioning

confidence: 99%

Fast Fabrication of Complex Surficial Micro-Features Using Sequential Lithography and Jet Electrochemical Machining

Saxena

Guo

et al. 2020

Micromachines

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This paper presents fabrication of complex surficial micro-features employing a cross-innovative hybrid process inspired from lithography and Jet-ECM. The process is referred here as mask electrolyte jet machining (MEJM). MEJM is a non-contact machining process which combines high resolution of lithography and greater flexibility of Jet-ECM. It is a non-contact process which can fabricate variety of microstructures on difficult-to-machine materials without need of expensive tooling. The presented work demonstrates the process performance of this technology by statistical analysis and multivariate kernel density estimation (KDE) based on probabilistic density function. Micro-letters are fabricated as an example of complex surficial structure comprising of multiple intersecting, straight and curved grooves. The processing response is characterized in terms of geometrical size, similarity ratio, and cumulative shape deviation. Experimental results demonstrated that micro letters with good repeatability (minimum SD of shape error ratio 0.297%) and shape accuracy (minimum shape error of 0.039%) can be fabricated with this technology. The results suggest MEJM could be a promising technology for batch manufacturing of surface microstructures with high productivity.

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A Review on Hybrid Micromachining Process and Technologies

Singh

Kunar

Zubairuddin

et al. 2023

Hybrid Micromachining and Microfabrication Technologies

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A tool-based hybrid laser-electrochemical micromachining process: Experimental investigations and synergistic effects

Cited by 55 publications

References 26 publications

Real-time on-machine observations close to interelectrode gap in a tool-based hybrid laser-electrochemical micromachining process

Real-time on-machine observations close to interelectrode gap in a tool-based hybrid laser-electrochemical micromachining process

Fast Fabrication of Complex Surficial Micro-Features Using Sequential Lithography and Jet Electrochemical Machining

A Review on Hybrid Micromachining Process and Technologies

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