Abstract
The coaxial laser has been introduced to shaped tube electrochemical machining (STEM), referred to as laser-STEM, to enhance the materials removal rate and precision. To address the issue of central residual formation during the laser-STEM process, which limited the machining stability and feeding rate, the retracted hybrid tubular electrode was applied. The formation mechanisms and effects of the W-shaped central residual were analyzed. Simulation and experiments were conducted to study the impact of the retracted length of the tubular electrode. Simulation results showed that a retracted length of 1–1.5 mm of the inner low-refractive layer could improve the electric current density distribution homogeneity to remove the W-shaped central residual in the machining area. The electric current density distribution homogeneity in the machining zone has been decreased by 38% by utilizing the hybrid tubular electrode with a retracted length of 2.0 mm. With a proper retracted length, the laser coupling efficiency exceeded 74.5%. Hence, the retracted hybrid tubular electrode could act as both the tool electrode and optical waveguide in the laser-STEM process. Experimental results proved that the machining efficiency and precision of laser-STEM could be enhanced by utilizing the retracted hybrid tubular electrode. With the retracted length deg rising from 0 to 1.5 mm, the maximum feeding speed increased by 373%, and the machining precision was improved by 42.2%. The maximum feeding rate of 4.1 mm/min has been achieved using the retracted hybrid tubular electrode in the laser-STEM process, which has been improved by 105%, compared with the available maximum feeding rate of the tubular electrode in the STEM process. Finally, the small holes with a diameter of 1.4 mm and an aspect ratio of 15 have been processed by laser-STEM with the retracted hybrid tubular electrode.
Highlights
Electrochemical machining (ECM) removes workpiece materials based on the controllable anodic dissolution process
When the retracted length deg rose to 2 mm, the simulation result demonstrated that the electric current line density distribution within the machining area increased, compared with that no retraction, that is, deg = 0
A retracted hybrid tubular electrode has been introduced to the hybrid Laser-shaped tube electrochemical machining (STEM) process to improve both the machining efficiency and precision
Summary
Electrochemical machining (ECM) removes workpiece materials based on the controllable anodic dissolution process. The contradiction between the formation of central residual and the high feeding rate of the tool electrode has to be resolved to improve both the machining efficiency and precision of STEM. The retracted hybrid tubular electrode has been introduced to improve both the machining precision and efficiency of the Laser-STEM process. A tubular electrode with the retracted inner layer, rather than the flat-end tool used in the previous studies, has been utilized for expanding the electric current density towards the machining area center. The residual, formed between the laser processing and electrochemical dissolution area, could be removed by the increased electric current density. The materials at the machining area could be removed much homogeneously, which is preferred to enhancing the machining stability and improving the feeding rate of the tubular electrode
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More From: The International Journal of Advanced Manufacturing Technology
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