Study on the Effect of Electrolytes on Processing Efficiency and Accuracy of Titanium Alloy Utilizing Laser and Shaped Tube Electrochemical Machining
Electrochemical machining (ECM) has become more prevalent in titanium alloy processing. However, the presence of the passivation layer on the titanium alloys significantly impacts the performance of ECM. In an attempt to overcome the passivation effects, a high-temperature electrolyte or the additio...
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| Format: | Article |
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MDPI AG
2024-01-01
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| Online Access: | https://www.mdpi.com/1996-1944/17/3/689 |
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| author | Chenyu Sun Yufeng Wang Yong Yang Zhehe Yao Yunfeng Liu Qiang Wu Jie Yan Jianhua Yao Wenwu Zhang |
| author_facet | Chenyu Sun Yufeng Wang Yong Yang Zhehe Yao Yunfeng Liu Qiang Wu Jie Yan Jianhua Yao Wenwu Zhang |
| author_sort | Chenyu Sun |
| collection | DOAJ |
| description | Electrochemical machining (ECM) has become more prevalent in titanium alloy processing. However, the presence of the passivation layer on the titanium alloys significantly impacts the performance of ECM. In an attempt to overcome the passivation effects, a high-temperature electrolyte or the addition of halogen ions to the electrolyte has been used. Still, it often results in compromised machining accuracy and surface roughness. This study applied laser and shaped tube electrolytic machining (Laser-STEM) for titanium alloy drilling, where the laser was guided to the machining zone via total internal reflection. The performance of Laser-STEM using different types of electrolytes was compared. Further, the effects of laser power and pulse voltage on the machining side gap, material removal rate (MRR), and surface roughness were experimentally studied while drilling small holes in titanium alloy. The results indicated that the use of passivating electrolytes improved the machining precision, while the MRR decreased with an increase in laser power during Laser-STEM. The MRR showed an increase while using aggressive electrolytes; however, at the same time, the machining precision deteriorated with the increase in laser power. Particularly, the maximum feeding rate of 6.0 mm/min for the tool electrode was achieved using NaCl solution as the electrolyte during Laser-STEM, marking a 100% increase compared to the rate without the use of a laser. Moreover, the model and equivalent circuits were also established to illustrate the material removal mechanisms of Laser-STEM in different electrolytes. Lastly, the processing of deep small holes with a diameter of 1.5 mm, a depth of 38 mm, and a surface roughness of Ra 2 µm was achieved via Laser-STEM without the presence of a recast layer and heat-affected zones. In addition, the cross-inner flow channels in the titanium alloys were effectively processed. |
| first_indexed | 2024-03-08T03:52:40Z |
| format | Article |
| id | doaj.art-5888129821684170816abdb306288775 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-08T03:52:40Z |
| publishDate | 2024-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-5888129821684170816abdb3062887752024-02-09T15:17:44ZengMDPI AGMaterials1996-19442024-01-0117368910.3390/ma17030689Study on the Effect of Electrolytes on Processing Efficiency and Accuracy of Titanium Alloy Utilizing Laser and Shaped Tube Electrochemical MachiningChenyu Sun0Yufeng Wang1Yong Yang2Zhehe Yao3Yunfeng Liu4Qiang Wu5Jie Yan6Jianhua Yao7Wenwu Zhang8College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, ChinaNingbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo 315201, ChinaNingbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo 315201, ChinaCollege of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, ChinaCollege of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, ChinaSuzhou Electric Machining Machine Tool Research Institute Co., Ltd., Suzhou 215011, ChinaSuzhou Electric Machining Machine Tool Research Institute Co., Ltd., Suzhou 215011, ChinaCollege of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, ChinaNingbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo 315201, ChinaElectrochemical machining (ECM) has become more prevalent in titanium alloy processing. However, the presence of the passivation layer on the titanium alloys significantly impacts the performance of ECM. In an attempt to overcome the passivation effects, a high-temperature electrolyte or the addition of halogen ions to the electrolyte has been used. Still, it often results in compromised machining accuracy and surface roughness. This study applied laser and shaped tube electrolytic machining (Laser-STEM) for titanium alloy drilling, where the laser was guided to the machining zone via total internal reflection. The performance of Laser-STEM using different types of electrolytes was compared. Further, the effects of laser power and pulse voltage on the machining side gap, material removal rate (MRR), and surface roughness were experimentally studied while drilling small holes in titanium alloy. The results indicated that the use of passivating electrolytes improved the machining precision, while the MRR decreased with an increase in laser power during Laser-STEM. The MRR showed an increase while using aggressive electrolytes; however, at the same time, the machining precision deteriorated with the increase in laser power. Particularly, the maximum feeding rate of 6.0 mm/min for the tool electrode was achieved using NaCl solution as the electrolyte during Laser-STEM, marking a 100% increase compared to the rate without the use of a laser. Moreover, the model and equivalent circuits were also established to illustrate the material removal mechanisms of Laser-STEM in different electrolytes. Lastly, the processing of deep small holes with a diameter of 1.5 mm, a depth of 38 mm, and a surface roughness of Ra 2 µm was achieved via Laser-STEM without the presence of a recast layer and heat-affected zones. In addition, the cross-inner flow channels in the titanium alloys were effectively processed.https://www.mdpi.com/1996-1944/17/3/689laser and electrochemical machiningpassivating electrolyteaggressive electrolytematerial removal mechanismsside gap |
| spellingShingle | Chenyu Sun Yufeng Wang Yong Yang Zhehe Yao Yunfeng Liu Qiang Wu Jie Yan Jianhua Yao Wenwu Zhang Study on the Effect of Electrolytes on Processing Efficiency and Accuracy of Titanium Alloy Utilizing Laser and Shaped Tube Electrochemical Machining Materials laser and electrochemical machining passivating electrolyte aggressive electrolyte material removal mechanisms side gap |
| title | Study on the Effect of Electrolytes on Processing Efficiency and Accuracy of Titanium Alloy Utilizing Laser and Shaped Tube Electrochemical Machining |
| title_full | Study on the Effect of Electrolytes on Processing Efficiency and Accuracy of Titanium Alloy Utilizing Laser and Shaped Tube Electrochemical Machining |
| title_fullStr | Study on the Effect of Electrolytes on Processing Efficiency and Accuracy of Titanium Alloy Utilizing Laser and Shaped Tube Electrochemical Machining |
| title_full_unstemmed | Study on the Effect of Electrolytes on Processing Efficiency and Accuracy of Titanium Alloy Utilizing Laser and Shaped Tube Electrochemical Machining |
| title_short | Study on the Effect of Electrolytes on Processing Efficiency and Accuracy of Titanium Alloy Utilizing Laser and Shaped Tube Electrochemical Machining |
| title_sort | study on the effect of electrolytes on processing efficiency and accuracy of titanium alloy utilizing laser and shaped tube electrochemical machining |
| topic | laser and electrochemical machining passivating electrolyte aggressive electrolyte material removal mechanisms side gap |
| url | https://www.mdpi.com/1996-1944/17/3/689 |
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