Author Affiliations
1School of Mechanical Engineering, Tianjin University, Tianjin 300072, China2Key Laboratory of Mechanism Theory and Equipment Design, Ministry of Education, School of Mechanical Engineering, Tianjin University, Tianjin 300072, China3State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China4Beijing Key Lab of Precision/Ultra-Precision Manufacturing Equipment and Control, Tsinghua University, Beijing 100084, Chinashow less
Fig. 1. Tubular electrode structure schematic diagrams. (a) Schematic diagram of fiber device and electrode device assembly; (b) schematic diagram of electrode device structure
Fig. 2. Logic diagram of laser action on complex energy field
Fig. 3. Schematic diagram of laser and electrolytic pulses
Fig. 4. Schematic diagram of laser and electrochemical hybrid machining mechanism
Fig. 5. Schematic diagram of all domains and boundaries of the tubular electrode-coupled laser and electrochemical hybrid model
Fig. 6. 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
Fig. 7. Cross-sectional profiles. (a) Cross-section near the cathode; (b) cross-section near the anode
Fig. 8. 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
Fig. 9. 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
Fig. 10. 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
Fig. 11. Side wall morphology of small holes with high aspect ratio. (a) 20 mm through-hole; (b) 50 mm through-hole
Parameter | Value | Unit |
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Voltage | 12 | V | Electrolyte conductivity | 12.5 | S/m | Initial electrolyte temperature | 293 | K | Workpiece material | DD6 | | Machining time | 1 | s | Interelectrode gap | 50 | μm | Laser power density | 5×107 | W/cm2 | Fiber diameter | 200 | μm | Current efficiency | 50% | | Density | 8780 | kg/m3 | Ideal gas constant | 8.314 | J/(mol·K) | Faraday constant | 96500 | C |
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Table 1. Simulation parameters
Parameter | Content |
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Electrolyte | NaNO3 (mass fraction:12%) | Electrolyte pressure | 1 MPa | Electrolytic voltage | 20 V | Laser wavelength | 532 nm | Laser pluse duration | 100 ns | Laser average power | 15,30 W | Laser repetition rate | 40 kHz | Fiber diameter | 220 μm | Outer diameter of tubular electrode | 0.8 mm |
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Table 2. Experimental parameters
Through-hole depth /mm | Parameter | Value |
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20 | Inlet diameter /mm | 1.26 | Outlet diameter /mm | 1.23 | Aspect ratio | 16∶1 | Taper /(°) | 0.04 | 50 | Inlet diameter /mm | 1.25 | Outlet diameter /mm | 1.11 | Aspect ratio | 42∶1 | Taper /(°) | 0.08 |
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Table 3. Experimental results