Application of laser and electrochemical interaction in sequential and hybrid micromachining processes

Skoczypiec, Sebastian

doi:10.1515/bpasts-2015-0035

Cited by 12 publications

(4 citation statements)

References 26 publications

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“…25 Also, the temperature rise in the machining area could improve the diffusion rate of the electrolytic products and reactant ions, leading to higher electric current density. The electric current density (i) during LECM-ITR could be described by following equation: 26 i = i 0 exp E 0 T RT 0 (T 0 + T ) [6] where E 0 is activation energy, T 0 is initial surface temperature. Thus, the electric current could at the machining area could be improved by the temperature rise.…”

Section: Discussionmentioning

confidence: 99%

Development of Laser and Electrochemical Machining Based on Internal Total Reflection

Wang

Yang

Zhang

2019

J. Electrochem. Soc.

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To address the issues of the existing laser and electrochemical machining (LECM) processes in controlling the machining precision, machining depth limit, and taper angle, a novel LECM based on internal total reflection (LECM-ITR) has been proposed. In LECM-ITR, both the electrolyte jet and laser beam were guided and transferred to the machining area, synchronously. Since the tube electrode could feed into the workpiece, the laser could act on the high depth machining area with less laser attenuation. The materials could be removed by using laser-materials interaction and electrochemical dissolution. Small holes with depth of 2 mm have been processed on aluminum alloy and stainless-steel workpiece successfully. Experimental results showed that LECM-ITR could decrease the side gap by 23.6%, reduce the taper angle by 60.8%, and improve materials removal rate by 118.8%. The mechanism of materials removal rate and precision enhancement by LECM-ITR were discussed, including (1) Laser induced temperature rise at the machining area could improve the machining efficiency of ECM with the increased electric current density; (2) The formed anodic oxide layer in larger thickness could enhance the machining precision of ECM with increasing time constant of the electric double layer at the machining area.

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Section: Discussionmentioning

confidence: 99%

Development of Laser and Electrochemical Machining Based on Internal Total Reflection

Wang

Yang

Zhang

2019

J. Electrochem. Soc.

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“…Results showed that the depth of the machined grooves increased when the laser power increased from 0 W to 6 W. The width of the microgrooves increased when the laser power increased from 0 W to 4 W, and then decreased with a laser power of larger than 4 W. The materials removal rate of the electrochemical machining was directly related to the electric current density in the machining zone, based on Faraday's law. The electric current density of the electrochemical dissolution can be expressed as [27]:…”

Section: Effects Of Laser Power On Laser-stemmentioning

confidence: 99%

Fabrication of Microgrooves by Synchronous Hybrid Laser and Shaped Tube Electrochemical Milling

et al. 2021

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The fabrication of deep microgrooves has become an issue that needs to be addressed with the introduction of difficult-to-cut materials and ever-increasing stringent quality requirements. However, both laser machining and electrochemical machining could not fulfill the requirements of high machining efficiency and precision with good surface quality. In this paper, laser and shaped tube electrochemical milling (Laser-STEM) were initially employed to fabricate microgrooves. The mechanisms of the Laser-STEM process were studied theoretically and experimentally. With the developed experimental setup, the influences of laser power and voltage on the width, depth and bottom surface roughness of the fabricated microgrooves were studied. Results have shown a laser power of less than 6 W could enhance the electrochemical machining rate without forming a deep kerf at the bottom during Laser-STEM. The machining accuracy or localization of electrochemicals could be improved with laser assistance, whilst the laser with a high-power density would deteriorate the surface roughness of the bottom machining area. Experimental results have proved that both the machining efficiency and the machining precision can be enhanced by synchronous laser-assisted STEM, compared with that of pure electrochemical milling. The machining side gap was decreased by 62.5% while using a laser power of 6 W in Laser-STEM. The laser-assistance effects were beneficial to reduce the surface roughness of the microgrooves machined by Laser-STEM, with the proper voltage. A laser power of 3 W was preferred to obtain the smallest surface roughness value. Additionally, the machining efficiency of layer-by-layer Laser-STEM can be improved utilizing a constant layer thickness (CLT) mode, while fabricating microgrooves with a high aspect ratio. Finally, microgrooves with a width of 1.79 mm, a depth of 6.49 mm and a surface roughness of 2.5 μm were successfully fabricated.

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“…• Reducing the heat induced defects of other micromachining technologies based on thermal principle of material removal such as micro-EDM, laser micromachining, etc. [203], [204], [210]- [214] For successful hybridization of micro-ECM with other process energies and realize it in machining, several technological requirements have to be met and are listed below:…”

Section: A C C E P T E D Accepted Manuscriptmentioning

confidence: 99%

A review on process capabilities of electrochemical micromachining and its hybrid variants

Saxena

Qian

Reynaerts

2018

International Journal of Machine Tools and Manufacture

193

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Electrochemical micromachining (micro-ECM) is an unconventional micromachining technology that has capability to fabricate high aspect ratio micro-holes, micro-cavities, microchannels and grooves on conductive and difficult-to-cut materials. Both academia and industry have the consensus that it offers promising machining performance especially in terms of high surface finish, no tool wear and absence of thermally induced defects. Furthermore in order to machine novel materials with extreme properties, novel hybrid electrochemical micromachining technologies are under development. With these hybrid micro-ECM technologies, capabilities of micro-ECM can be expanded by combining it with other processes. To fully exploit the potential as well as improve micro-ECM technology and related hybrid processes, a wide spectrum of multidisciplinary knowledge is needed. The present review systematically discusses process capabilities and research developments of electrochemical micromachining and its hybrid variants considering knowledge of both basic and applied research fields. After few introductory review articles in prior state of the art, this review fills an important gap in research literature by presenting first time an extended literature source with a wide coverage of recent research developments in electrochemical micromachining technology and its hybrid variants. This paper outlines the research and engineering developments in electrochemical micromachining technology and its hybrid variants, review of the related concepts, aspects of tooling, advanced process capabilities and process energy sources. It also provides new sights into technological understanding of micro-ECM technology which will be helpful in future engineering developments of this technology.

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Application of laser and electrochemical interaction in sequential and hybrid micromachining processes

Cited by 12 publications

References 26 publications

Development of Laser and Electrochemical Machining Based on Internal Total Reflection

Development of Laser and Electrochemical Machining Based on Internal Total Reflection

Fabrication of Microgrooves by Synchronous Hybrid Laser and Shaped Tube Electrochemical Milling

A review on process capabilities of electrochemical micromachining and its hybrid variants

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