Multi‐Physical Field Coupling Analysis and Experimental Research in Annular Laser and Tube‐Electrode Electrochemical Hybrid Processing for Small Holes with Large Depth‐to‐Diameter Ratios

Yongbo Xu; Han Hu; Wanda Xie; Ke Chen; Ye Ding; Hao Tong; Lijun Yang

doi:10.3788/CJL241200

Chinese Journal of Lasers, Volume. 52, Issue 4, 0402405(2025)

Multi‐Physical Field Coupling Analysis and Experimental Research in Annular Laser and Tube‐Electrode Electrochemical Hybrid Processing for Small Holes with Large Depth‐to‐Diameter Ratios

Yongbo Xu¹, Han Hu², Wanda Xie¹, Ke Chen¹, Ye Ding^1,4, Hao Tong^2、*, and Lijun Yang^1,3、**

Author Affiliations

¹School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, Heilongjiang , China

²Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China

³Chongqing Research Institute, Harbin Institute of Technology, Chongqing 401151, China

⁴Suzhou Research Institute, Harbin Institute of Technology, Suzhou 215104, Jiangsu , China

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Figures & Tables(17)

Fig. 1. Schematic diagrams of hybrid machining device and electrode for hybrid machining. (a) Hybrid machining device; (b) electrode for hybrid machining

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Fig. 2. Multi-physical field coupling mechanisms in annular laser and tube-electrode electrochemical hybrid machining

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Fig. 3. Simulation model of annular laser and tube-electrode electrochemical hybrid machining. (a) 2D symmetric simulation model; (b) magnified detail in Fig.3(a)

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Fig. 4. Distributions of flow fields in hybrid processing. (a) Flow field distribution within inter-electrode gap; (b) flow speeds on workpiece surface under different inter-electrode gaps; (c) flow speeds in inter-electrode gap under different entrance pressures; (d) flow speed at line under different depth-to-diameter ratios

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Fig. 5. Distributions of temperature fields in hybrid processing. (a) Interaction process between hybrid energy field and material; (b) relationship between workpiece surface temperature and machining time; (c) enlarged view at A in Fig.5(b); (d) variation of electrolyte temperature with machining time; (e) enlarged view at B in Fig.5(d)

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Fig. 6. Distributions of current density values in hybrid processing. (a) Relationship among voltage, laser power and surface current density of workpiece in hybrid machining process; (b) enlarged view in Fig. 6(a)

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$Distributions of gases in hybrid processing. (a) Variation of overall gas volume fraction with processing voltage and laser power; (b) relationship among processing voltage, laser power and gas volume fraction at 25 μm from workpiece surface$

Fig. 7. Distributions of gases in hybrid processing. (a) Variation of overall gas volume fraction with processing voltage and laser power; (b) relationship among processing voltage, laser power and gas volume fraction at 25 μm from workpiece surface

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Fig. 8. Distributions of electrolyte conductivities in hybrid processing. (a) Relationship between processing voltage and conductivity without laser; (b) relationship between laser power and conductivity in hybrid machining process

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Fig. 9. Variations of material removal depths in hybrid processing. (a) Relationship between processing voltage and removal depth when laser power is 0‒10 W; (b) enlarged view in Fig.9(a); (c) relationship between processing time and removal depth with laser power of 25 W

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Fig. 10. Morphologies and microstructures of deep small holes. (a) Optical morphology of deep small hole in electrochemical machining; (b) optical morphology of deep small hole in hybrid machining; (c) SEM image of deep small hole in hybrid machining; (d) enlarged view of region A in Fig.10(c); (e) enlarged view of region B in Fig.10(c)

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Fig. 11. Elemental distributions for regions A and B in Fig. 10(c). (a)(e) Ti; (b)(f) V; (c)(g) Al; (d)(h) O; (i)(j) EDS results

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Fig. 12. Roughness values of deep small holes prepared by electrochemical machining (ECM) and hybrid machining (LECHM)

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Fig. 13. Annular laser and tube-electrode electrochemical hybrid machining mechanism and material removal mechanism

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Table 1. Boundary conditions

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Table 1. Boundary conditions

Physical field	Parameter	Setting
Flowing field	Entrance pressure at Г₁ Exit pressure at Г₆ and Г₇ Hydrogen flux at Г₁₁， Г₁₅ and Г₁₆ Oxygen flux at Г₈， Г₉， Г₁₁ and Г₁₇	1.0‒2.5 MPa 0 MPa $N_{H_{2}}$ $N_{O_{2}}$
Electrochemical field	Anode voltage at Г₈， Г₉， Г₁₂ and Г₁₇ Cathode voltage at Г₁₁， Г₁₅ and Г₁₆	10‒30 V 0 V
Temperature field	Heat source at Г₁₂	$Q_{J} + Q_{a}^{'}$
Structural field	Normal grid moving speed at Г₁₂	v'

Table 2. Parameters used in simulation

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Table 2. Parameters used in simulation

Parameter	Value
Electrolyte thermal conductivity $k_{e}$	6.81 W/（m/K）
Electrolyte dynamic viscosity $μ$	0.001 Pa·s
Electrolyte conductivity σ₀	13.3 S/m
Electrolyte density $ρ$	1100 kg/m³
Workpiece density $ρ_{w}$	4540 kg/m³
Workpiece capacity $C_{p}$	395 J/（kg·K）
Workpiece thermal conductivity $k_{w}$	6.81 W/（m/K）
Wavelength	532 nm
Repetition frequency	50 kHz
Pulse width	5 μs
Duty cycle	50%
Laser power	20‒50 W
Depth-to-diameter ratio	10‒50
Simulation time	500 μs
Inter-electrode gap （IEG）	25‒100 μm

Table 3. Chemical compositions of TC4 alloy
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Table 3. Chemical compositions of TC4 alloy
Element Al V Fe C N H O Ti
Mass fraction /% 4.0700 6.1400 0.0750 0.0160 0.0220 0.0015 0.1000 Bal.

Table 4. Parameters used in experiment

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Table 4. Parameters used in experiment

Parameter	Content
Workpiece material	TC4
Materials of tube 1 and tube 2	304 stainless steel
Voltage	30 V
Pulse width	10 μs
Duty cycle	50%
Laser power	0 W and 15 W
Wavelength	532 nm
Repetition frequency	50 kHz
IEG	100 μm
Flow speed	140 mL/min
Feeding speed	1.0 mm/min
Machining depth	15 mm

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Yongbo Xu, Han Hu, Wanda Xie, Ke Chen, Ye Ding, Hao Tong, Lijun Yang. Multi‐Physical Field Coupling Analysis and Experimental Research in Annular Laser and Tube‐Electrode Electrochemical Hybrid Processing for Small Holes with Large Depth‐to‐Diameter Ratios[J]. Chinese Journal of Lasers, 2025, 52(4): 0402405

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