Multi-energy field simulation and experimental research on laser composite machining of micro-holes

• Published in: Journal of applied physics 2024-06, Vol.135 (23)
• Format: Article
• Language: English
• Subjects: Cutting force; Electrolytes; Laser machining; Lasers; Liquid phases; Mass transfer; Microholes; Oxygen content; Precision machining; Surface roughness; Thermal energy; Thin walls
• ISSN: 0021-8979; 1089-7550
• DOI: 10.1063/5.0202279

Thin-walled micro-holes are frequently used in aerospace components to achieve specific functions, such as heat dissipation and filtration. However, traditional manufacturing technologies face difficulties in achieving precision machining of these holes due to deformation caused by cutting force or heat. Laser machining is a highly flexible and efficient advanced processing technology that aims to achieve precise machining of thin-walled holes. However, it is important to note that the thermal energy generated by the laser can cause deformation of the thin walls. To address these issues, this paper proposes a process that combines laser and backside electrochemical composite machining. The model for laser electrochemical composite processing after through-hole formation suggests that the laser's temperature rise effect on the electrolyte can significantly enhance the efficiency of electrochemical processing. Furthermore, the laser exerts a micro-zone stirring effect on the electrolyte in the processed micro-zone, which promotes the liquid-phase mass transfer process during the electrochemical reaction. Furthermore, a one-way experiment was conducted to investigate the effects of the main laser parameters on the processing results. The results indicated that higher laser power, as well as lower laser frequency and scanning speed, significantly reduced the edge damage and pore taper of the processed micro-holes. The language used is clear, concise, and objective, adhering to a formal register and avoiding biased or ornamental language. Technical terms are consistently used and explained when first introduced. The text is grammatically correct and free from spelling and punctuation errors. Furthermore, this process has significantly reduced the oxygen content and surface roughness of the sidewalls of the micro-holes.