Mr. Yu lei Li Profile

Yu lei Li

at Ningbo Institute of Materials Technology and Engineering

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Proceedings Article | 16 December 2022 Paper

Study of the influence of conical guide on laser coupling stability in laser and electrochemical machining by optical simulation

Yulei Li, Yufeng Wang, Yong Yang, Wenwu Zhang

Proceedings Volume 12501, 125010C (2022) https://doi.org/10.1117/12.2655297

KEYWORDS: Fiber lasers, Liquids, Electrodes, Laser energy, Optical simulations, Laser processing, Energy efficiency, Laser stabilization, Refractive index, Fiber coupled lasers

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Laser and shaped tube electrochemical machining (Laser-STEM) has been proposed to process small holes with high efficiency and surface quality. In Laser-STEM the laser energy is transmitted to the machining zone with high efficiency by total internal reflection confined in the inner hole of the tool electrode. Coupling between the laser and the tool electrode is of importance to guarantee the stability and accuracy of the Laser-STEM process. The previous studied focuses the laser beam to the entrance of the tool electrode utilizing a focusing lens. However, the method was easily affected by the focal length, spot size, and installation error, which would influence laser coupling stability and transmission efficiency. This paper focuses on the research of a novel laser coupling method based on the conical optical guide to improve the coupling robustness. Mathematical model of the laser propagation through the conical guide has been derived. The maximum coupling angle of the conical guide with different sizes was obtained. The effect of laserliquid- core fiber tool electrode coupling error on laser energy coupling efficiency is investigated by optical simulation, and the feasibility of conical light-guiding devices for efficient conduction of laser energy was verified experimentally. Results showed that the conical optical guide could improve the laser axial incidence range by about 3 times, the radial range by 2 times, and the angular coupling range by 1.9 times, with the laser coupling efficiency of 90%. The introduction of the conical guide remarkably improved the coupling efficiency and stability of the laser and tool electrode, which is of great significance for improving the stability of Laser-STEM.

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