低损伤大深度小孔在航空航天、精密机械等领域需求日益迫切，其高效高质制造技术已成为国内外研究热点。为满足深小孔加工对加工深度、表面质量和加工效率等的综合要求，本项目提出基于激光与管电极电解同步复合的低损伤大深度小孔加工技术，综合利用激光加工、电解加工及其耦合效应，实现大深度精密小孔的高效加工。通过固体边界全光导约束效应将激光能量场同步传导至加工区域，结合管电极的大深度进给，采用内孔高速冲液和电极旋转促进产物排出，实现大深度加工区域的激光与电化学能量场的持续耦合介入和材料高效去除。本项目重点研究基于固体边界全光导约束的激光与电化学能量场耦合机制，揭示激光与管电极电解同步复合低损伤大深度加工机理，建立加工间隙演化数学模型，突破液核光纤管电极制备、激光-管电极耦合装置设计、加工状态特征参数提取与分析、过程控制、工艺参数匹配等关键技术，拓展低损伤大深度小孔高效制造的工艺极限。

Low damage and large depth small holes are increasingly needed in various fields, such as aerospace and precision machinery. The high-efficiency high-quality fabrication of low damage and high aspect ratio small holes has become a research focus, home and abroad. To address the issues of machining depth, efficiency and surface quality in the large-depth small hole drilling process, this project proposed the synchronized laser and shaped tube electrochemical hybrid machining (Laser-STEM) to process low damage and large depth small holes. Laser-STEM could be applied to fabricate large depth and low damage small holes in high efficiency, combining the advantages of laser beam machining, electrochemical etching and the coupling effects. In the laser-STEM process, laser beam could be transmitted to the machining area via the internal total reflection induced by a solid boundary constraint, and the machining products could be flown away from the machining gap by internal electrolyte flushing and rotary tube electrode in high efficiency, thus the laser and electrochemical hybrid machining could occur in large depth, with the feeding of the tube electrode into the workpiece. This project will in depth explore the controllable coupling mechanism of laser and electrochemical fields based on the solid boundary constrained layer induced internal total reflection, study the materials removal mechanisms of laser and electrochemical hybrid machining method in which multi-fields are coupled in the deep machining zone, and develop a dynamical mathematical model of the varying machining gap during the Laser-STEM process. Moreover, this project will also focus on the key technologies such as the establishment of liquid cored tube electrode and the design of the laser-tube electrode coupling system, the monitoring of the hybrid machining status, and the process characteristics of the laser-STEM process. Thus, this project will process deep small precision holes, with high surface quality and high machining efficiency, extending the current process limits.