A new laser-induced plasma electrolyte jet machining method: Efficient material removal mechanism and synergistic effects

Abstract

Laser electrolytic hybrid machining methods still present a more significant challenge regarding material removal rates due to the high energy loss of the laser in the electrolyte column and the low conductivity electrolyte column between the electrodes. In this paper, a laser-induced plasma electrolyte jet machining method is proposed for the first time to overcome the above problems. Specifically, the short propagation distance of the laser beam in the electrolyte column in the laser-induced plasma electrolyte jet machining method reduces the laser energy loss. In addition, a plasma is formed between the cathode and anode to reduce the ohmic voltage drop between the electrodes. Compared to conventional laser-electrolytic hybrid machining, the introduction of plasma into electrolyte jet machining leads to a significant difference in machining performance. The evolution of laser-induced plasma channels and the enhancement of plasma shocks under the jet liquid film are demonstrated. The material removal mechanism and laser-induced plasma electrolyte jet machining characteristics are comprehensively investigated. The grooves were finally machined using the proposed laser-induced plasma electrolyte jet machining method, and a material removal rate of 2.23 mm3/min was obtained. This study significantly increased the material removal rates of the laser electrolytic hybrid machining technique.