Improving performance of laser and shaped tube electrochemical machining by using retracted hybrid tubular tool electrode
Improving performance of laser and shaped tube electrochemical machining by using retracted hybrid tubular tool electrode
复制标题
使用缩回混合管状工具电极提高激光和异型管电化学加工的性能
DOI：
10.1007/s00170-021-08097-w
复制
发表时间：
2021-09-22
影响因子：
3.4
通讯作者：
Zhang, Wenwu
中科院分区：
文献类型：
--
作者：
Yang, Yong;Wang, Yufeng;Zhang, Wenwu
将同轴激光器引入到异型管电解加工中，以提高材料去除率和加工精度。为了解决激光-STEM加工过程中中心残留物形成的问题，这限制了加工稳定性和进给速率，应用了缩回的混合管状电极。分析了W形中心残余的形成机理和影响。通过仿真和实验研究了管状电极的回缩长度对测量结果的影响。仿真结果表明，内低折射层收缩长度为1 ~ 1.5 mm时，可以改善电流密度分布的均匀性，消除加工区域的W形中心残留。采用回缩长度为2.0mm的混合管状电极，加工区电流密度分布均匀性降低了38%，在合适的回缩长度下，激光耦合效率超过74.5%。因此，缩回的混合管状电极可以在激光-STEM过程中充当工具电极和光波导。实验结果表明，采用可收缩的混合管状电极可以提高激光-STEM的加工效率和加工精度。随着回缩长度度从0增加到1.5 mm，最大进给速度提高了373%，加工精度提高了42.2%。在激光-STEM工艺中使用缩回的混合管状电极已经实现了4.1mm/min的最大进给速率，与STEM工艺中管状电极的可用最大进给速率相比，其已经提高了105%。最后，具有1.4 mm的直径和纵横比为15的小孔已经通过激光STEM与缩回的混合管状电极加工。
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.