Study on Precision Microholes Using Pulsed Laser with Jet Electrochemical Machining

Abstract

The precision machining basically in the micron domain is a great challenge for advanced manufacturing industries. The assistance of laser beam with jet electrochemical machining process will localize the machining zone and helps to electrochemical dissolution of metal from the specific area which improves the machining quality and precision. Keeping in view, a hybrid laser-assisted jet electrochemical machine (LA-JECM) has been indigenously developed and utilized for microhole drilling experiments. The assistance of laser beam increases localization effect by increasing and maintaining the temperature in a predominant mode. A low-power Nd:YAG diode-pumped solid-state laser beam of wavelength 532 nm is used concentrically with electrolytic jet and carefully monitored its application; otherwise, electrolyte will start to boil due to supply of high laser beam energy and hamper the precision. The percentage of reduction in taper, overcut and average spark-affected zone are 32.3; 27.8; and 50.2%, respectively, when machining operations were carried out on LA-JECM over jet electrochemical machine. Taguchi method-based design of experiments is employed for experimental investigation, and acquired results are utilized for optimization of LA-JECM parameters for further improvement and precision.