Development of Laser and Electrochemical Machining Based on Internal Total Reflection

Wang, Yufeng; Yang, Feng; Zhang, Wenwu

doi:10.1149/2.0471914jes

Cited by 19 publications

(11 citation statements)

References 27 publications

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“…Therefore, the laser could transfer to the machining zone through the hybrid tubular electrode with high efficiency, and the hybrid tubular electrode could not be damaged by the leaked laser as well. Our previous study showed that the laser transmission efficiency in the electrolyte of 12.5% wt NaNO 3 solution could be larger than 75%, 19 and proved that laser could be transferred to the machining area through the inner hole of the hybrid tubular electrode. With an input laser source of Gaussian distribution input to the hybrid tubular electrode, the distribution of the output laser intensity at the exit also complied with the Gaussian distribution.…”

Section: Mechanisms Of Lstemmentioning

confidence: 95%

Profile Characteristics and Evolution in Combined Laser and Electrochemical Machining

Wang

Yang

et al. 2022

J. Electrochem. Soc.

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Machining small holes with high efficiency and high surface quality remains a challenging issue. Laser and shaped tube electrochemical machining (LSTEM) has been proposed to process small holes, in which material removal is by a combination of laser processing and enhanced electrochemical machining. This study explored the evolution and characteristics of the machined profile of LSTEM to elucidate its material removal mechanisms. Results showed that these are related to the interelectrode gap (IEG) and laser power. LBM dominated the material removal process when the IEG was larger than 0.2 mm. When the laser power was greater than 4 W, the material at the central machining area could be directly removed by LBM with higher efficiency than ECM, and the central depth was larger than the surrounding depth in the machining zone. Variation of the electric current in the machining process has been acquired to monitor the status of LSTEM. Small holes with depths of 6.5 and 60 mm have been machined. Further, small holes with diameters of 1.35 mm were fabricated on the thermal barrier coated workpiece by LBM and LSTEM successively.

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Section: Mechanisms Of Lstemmentioning

confidence: 95%

Profile Characteristics and Evolution in Combined Laser and Electrochemical Machining

Wang

Yang

et al. 2022

J. Electrochem. Soc.

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“…Using non-oxidation-assisted gases, an ideal hole shape with smooth sidewalls can be obtained, and the inner surface was smoother. Wang et al [16] proposed a laser-electrolytic coaxial simultaneous machining technology (Laser-STEM), which can reduce the side gap by 23.6 %, reduce the cone angle by 60.8 %, and increase the material removal rate by 118.8 %. Silva et al [17] combined lowpower laser (375 mW) with jet electrolysis to process aluminum alloy and stainless steel.…”

Section: Introductionmentioning

confidence: 99%

Feasibility study of laser and in-situ ECM of array holes

Shao

Yang

Wang

et al. 2022

Seventeenth National Conference on Laser Technology and Optoelectronics

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Aiming at the issues of low machining efficiency and difficulty in keeping consistency of machining accuracy of micro array holes with high surface quality. This paper proposed a laser and in-situ electrolytic machining technology for processing array holes, which utilized the advantages of high laser machining efficiency and good surface quality electrochemical machining (ECM). Firstly, laser was used to perform high-efficiency drilling of prefabricated micro array holes on workpieces that was covered with insulating layer, and then the recast layer and taper of prefabricated holes were removed by ECM. To verify the feasibility of the proposed method, laser prefabricated of the array holes with the diameter of 0.8 mm and the in-situ electrolytic recast layer removal were carried out on the Inconel 718 workpiece. Influences of laser scanning speed, defocusing distance, scanning times and insulating plate thickness on the taper of prefabricated hole were investigated experimentally. The optimized laser processing parameters were as follows: scanning speed 60 mm/s, defocusing distance 1.5 mm, scanning times 50, and insulating plate thickness 0.4mm. Results of in-situ ECM showed that the recast layer on the surface of the laser processed holes could be removed, indicating that the laser and in-situ ECM could achieve high efficiency and high precision machining of micro array holes without recast layer.

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“…Hybrid laser and shaped tube electrochemical machining (Laser-STEM) utilize a hybrid tubular electrode as both the cathode for ECM and an optical guide for the laser beam [21]. Laser-STEM combined the advantages of laser-material interaction, electrochemical machining, and laser-electrochemical interaction, which could make the material removal efficiency on the front machining gap continuously maintained at a high level [22].…”

Section: Introductionmentioning

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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Development of Laser and Electrochemical Machining Based on Internal Total Reflection

Cited by 19 publications

References 27 publications

Profile Characteristics and Evolution in Combined Laser and Electrochemical Machining

Profile Characteristics and Evolution in Combined Laser and Electrochemical Machining

Feasibility study of laser and in-situ ECM of array holes

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

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