研究目的
To address the issues of the existing laser and electrochemical machining (LECM) processes in controlling the machining precision, machining depth limit, and taper angle.
研究成果
LECM-ITR was used to process small holes with depth of 2 mm and small taper angle on aluminum alloy and stainless steel, which is not obtained by existing LECM. The laser beam could transfer to the machining area through the tube electrode inner hole by internal total reflection. Increasing the laser power could improve the materials removal rate and precision of ECM. Experimental analysis revealed that LECM-ITR could decrease the side gap by 23.6%, reduce the taper angle by 60.8%, and improve MRR by 118.8%.
研究不足
The processing depth of existing LECM technique has been seriously restricted within 0.5 mm range by serious laser attenuation, due to the obstructing and scattering effects of the electrolysis and micro bubbles in the machining area.
1：Experimental Design and Method Selection:
A novel LECM based on internal total reflection (LECM-ITR) was proposed where both the electrolyte jet and laser beam were guided and transferred to the machining area synchronously.
2：Sample Selection and Data Sources:
Workpiece of aluminum alloy 7075 and stainless steel 304 were processed. A 10% sodium chloride solution was used as the electrolyte.
3：List of Experimental Equipment and Materials:
A laser with a wavelength of 532 nm, a fluoropolymer Teflon layer with a thickness of
4：075 mm, and refractive index of 29 was attached to the tube electrode inner wall. Experimental Procedures and Operational Workflow:
The laser beam was focused to the tube electrode entrance and transferred to the exit via internal total reflection. The workpiece materials were removed by the combined effects of laser-materials interaction and electrochemical dissolution.
5：Data Analysis Methods:
The machining precision was represented by the side gap and taper angle. The dimension of the small holes was measured using a laser microscope and a scanning electron microscope.
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