There is a heat-affected zone in laser processing that affects the quality of the process. However, laser and tube electrode electrolytic composite processing has no heat-affected zone and no microcracking processing method. This method is subject to plasma breakdown during the machining process, which affects the quality of the machining. A real-time observation platform has been set up for the study of laser transport stability mechanisms in electrolytes. Focusing lens electrolyte breakdown, laser power density, breakdown frequency threshold, etc. were studied for 25mm, 50mm, and 77mm focal lengths, and it was found that breakdown was not easy to occur under the 77mm focusing lens. On the basis of this research on the tube electrode length, laser incidence angle, and other factors affecting the stability of processing, it was found that the laser incidence angle has an impact on the laser energy density distribution, but does not affect the laser focusing center of gravity position, and the increase in the length of the tube electrode helps to improve the laser energy density distribution. Using this processing method, a large depth grating-type workpiece was successfully processed on stainless steel, verifying the stability of the method of laser and tube electrode electrolytic composite processing.
With the increasing application of titanium alloys (Ti-6Al-4V) in aero engineering, great challenges have been posed to improve the surface quality and machining accuracy of titanium alloy. Titanium alloy is difficult to be processed. The existing processes suffer from thermal damage or low-efficiency. In this paper, laser and shaped tube electrochemical machining (Laser-STEM) has been employ to process titanium alloy, in which both the laser beam and electrolyte jet are guided to the machining zone through the inner hole of a specially designed tubular electrode. The processing characteristics of TC4 titanium under different processing voltages, laser power, and feeding rates were experimentally studied, while using sodium nitrate as the electrolyte. Influences of key process parameters on the machining profile size and surface roughness was explored. Results showed that the deep and narrow grooves with a good surface profile can be obtained under the voltage of about 20 V, laser power of 3 W, and electrode feeding rate of 1.8 mm/min. Finally, the rectangular wave slot with an average width of 1.6 mm and depth of 0.759 mm was machined by a layer-by-layer laser and electrochemical machining method. The feasibility of laser and shaped tube electrochemical hybrid machining of TC4 titanium alloy with high precision and efficiency has been verified, which laid a foundation for the application of this process in aerospace manufacturing.
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