Abstract
Laser drilling and electrochemical machining (LD-ECM) of metal micro-hole is proposed in this study. First of all, millisecond pulsed laser is directly focalized on the surface of metal in auxiliary gas. A prefabricated hole is rapidly drilled, and recast layer is formed. Then, the recast layer on the hole wall is removed in electrochemical machining. Processing quality is improved. The cooling effect of auxiliary gas is considered to model the temperature field of laser drilling. The complex problem of laser heating a metal in gas is solved. The effect of gas-liquid two-phase flow on electrolyte conductivity is considered to couple physical fields of electrochemical machining. The practical problem of electrochemical solution of metal in the inter-electrode gap is solved. An accurate model of LD-ECM is established. The final shape of a metal micro-hole is calculated by the simulation results of LD-ECM. The experimental results show that the simulation results are reasonable.
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