• Chinese Journal of Lasers
  • Vol. 51, Issue 16, 1602402 (2024)
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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    DOI: 10.3788/CJL231182 Cite this Article Set citation alerts
    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 Copy Citation Text show less
    Tubular electrode structure schematic diagrams. (a) Schematic diagram of fiber device and electrode device assembly; (b) schematic diagram of electrode device structure
    Fig. 1. 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
    Fig. 2. Logic diagram of laser action on complex energy field
    Schematic diagram of laser and electrolytic pulses
    Fig. 3. Schematic diagram of laser and electrolytic pulses
    Schematic diagram of laser and electrochemical hybrid machining mechanism
    Fig. 4. 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
    Fig. 5. 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
    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
    Cross-sectional profiles. (a) Cross-section near the cathode; (b) cross-section near the anode
    Fig. 7. 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
    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
    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. 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
    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. 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
    Side wall morphology of small holes with high aspect ratio. (a) 20 mm through-hole; (b) 50 mm through-hole
    Fig. 11. Side wall morphology of small holes with high aspect ratio. (a) 20 mm through-hole; (b) 50 mm through-hole
    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 1. Simulation 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 2. Experimental parameters
    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
    Table 3. Experimental results
    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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