Chinese Journal of Lasers, Volume. 51, Issue 16, 1602402(2024)

Theoretical Analysis and Experimental Research on Tubular Electrode‑Coupled Laser and Electrochemical Hybrid Machining

Xue Yang1,2, Chengjuan Yang1,2、*, Hao Tong3,4, Huimin Qi1,2, Yao Yao3,4, and Zhen Yang1,2
Author Affiliations
  • 1School of Mechanical Engineering, Tianjin University, Tianjin 300072, China
  • 2Key Laboratory of Mechanism Theory and Equipment Design, Ministry of Education, School of Mechanical Engineering, Tianjin University, Tianjin 300072, China
  • 3State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China
  • 4Beijing Key Lab of Precision/Ultra-Precision Manufacturing Equipment and Control, Tsinghua University, Beijing 100084, China
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    Figures & Tables(14)
    Tubular electrode structure schematic diagrams. (a) Schematic diagram of fiber device and electrode device assembly; (b) schematic diagram of electrode device structure
    Logic diagram of laser action on complex energy field
    Schematic diagram of laser and electrolytic pulses
    Schematic diagram of laser and electrochemical hybrid machining mechanism
    Schematic diagram of all domains and boundaries of the tubular electrode-coupled laser and electrochemical hybrid model
    Simulation results of tubular electrode-coupled laser and electrochemical hybrid machining. (a)‒(c) Flow field distributions at different time; (d)‒(f) pressure distributions at different time; (g)‒(i) electric filed distributions at different time; (j)‒(l) temperature distributions at different time
    Cross-sectional profiles. (a) Cross-section near the cathode; (b) cross-section near the anode
    Variations of workpiece surface temperature, electrolyte velocity, electrolyte current density, and Z-direction material removal with machining depth and processing time. (a)(b) Variation of workpiece surface temperature; (c)(d) variation of electrolyte velocity; (e)(f) variation of electrolyte current density; (g)(h) variation of with Z-direction material removal
    Three-dimensional morphology of blind hole cross-section. (a) Three-dimensional morphology of blind hole cross-section in electrochemical machining; (b) three-dimension morphology of blind hole cross-section in laser and electrochemical hybrid machining
    Morphologiy of small holes with high aspect ratio and local magnified images of the small holes edge, where the first row shows the small holes entrance, the second row shows small holes cross-section, and the third row shows the small holes exit
    Side wall morphology of small holes with high aspect ratio. (a) 20 mm through-hole; (b) 50 mm through-hole
    • Table 1. Simulation parameters

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      Table 1. Simulation parameters

      ParameterValueUnit
      Voltage12V
      Electrolyte conductivity12.5S/m
      Initial electrolyte temperature293K
      Workpiece materialDD6
      Machining time1s
      Interelectrode gap50μm
      Laser power density5×107W/cm2
      Fiber diameter200μm
      Current efficiency50%
      Density8780kg/m3
      Ideal gas constant8.314J/(mol·K)
      Faraday constant96500C
    • Table 2. Experimental parameters

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      Table 2. Experimental parameters

      ParameterContent
      ElectrolyteNaNO3 (mass fraction:12%)
      Electrolyte pressure1 MPa
      Electrolytic voltage20 V
      Laser wavelength532 nm
      Laser pluse duration100 ns
      Laser average power15,30 W
      Laser repetition rate40 kHz
      Fiber diameter220 μm
      Outer diameter of tubular electrode0.8 mm
    • Table 3. Experimental results

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      Table 3. Experimental results

      Through-hole depth /mmParameterValue
      20Inlet diameter /mm1.26
      Outlet diameter /mm1.23
      Aspect ratio16∶1
      Taper /(°)0.04
      50Inlet diameter /mm1.25
      Outlet diameter /mm1.11
      Aspect ratio42∶1
      Taper /(°)0.08
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    Xue Yang, Chengjuan Yang, Hao Tong, Huimin Qi, Yao Yao, Zhen Yang. Theoretical Analysis and Experimental Research on Tubular Electrode‑Coupled Laser and Electrochemical Hybrid Machining[J]. Chinese Journal of Lasers, 2024, 51(16): 1602402

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    Paper Information

    Category: Laser Micro-Nano Manufacturing

    Received: Sep. 8, 2023

    Accepted: Nov. 6, 2023

    Published Online: Mar. 22, 2024

    The Author Email: Yang Chengjuan (cjytju@tju.edu.cn)

    DOI:10.3788/CJL231182

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