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<p>This study addresses efficiency limitations in laser hybrid electrochemical machining (LECM) of high aspect-ratio micro holes in TC4 titanium alloy. Through morphological and EDS analysis of hole bottoms, it is identified that machining rate is constrained by: nonuniform electrochemical dissolution in Area III, and poor waste electrolyte renewal causing precipitate and gas accumulation. A synergistic strategy combining the insulation layer retraction and high-temperature electrolyte to enhance the machining efficiency was firstly proposed. Finite element simulations reveal that using high-temperature electrolyte enhances current density and dissolution homogeneity, while tubular electrodes with insulation layer retraction improve discharge flow velocity and electric field distribution. Experimental validation optimized the retraction distance and electrolyte temperature which could improve machining rate and ensure hole accuracy. Ultimately, the holes of 75&#xa0;mm deep were fabricated at 5.1&#xa0;mm/min employing above two techniques for the first time, representing an enhancement of 112.5% on machining efficiency. And the maximum processing speed fabricating shallow holes reaches 7&#xa0;mm/min which is increased by 16.7% compared to conventional LECM. Synergistic use of high temperature electrolytes and insulation layer retraction effectively breaking through the hole machining efficiency ceiling of LECM, furnishing a new method for micro hole fabrication in aero-engine components.</p>

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Experimental and simulation study on maximum machining rate of micro holes in laser electrochemical machining of TC4

  • 期刊论文

  • 发表日期：

    2026年1月26日

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  • Chengjuan Yang,
  • Chenxu Wang,
  • Zhenlei Li,
  • Xuesong Chen,
  • Xue Yang,
  • Mingyue Yin,
  • Wenjun Wang,
  • Zhen Yang

摘要

This study addresses efficiency limitations in laser hybrid electrochemical machining (LECM) of high aspect-ratio micro holes in TC4 titanium alloy. Through morphological and EDS analysis of hole bottoms, it is identified that machining rate is constrained by: nonuniform electrochemical dissolution in Area III, and poor waste electrolyte renewal causing precipitate and gas accumulation. A synergistic strategy combining the insulation layer retraction and high-temperature electrolyte to enhance the machining efficiency was firstly proposed. Finite element simulations reveal that using high-temperature electrolyte enhances current density and dissolution homogeneity, while tubular electrodes with insulation layer retraction improve discharge flow velocity and electric field distribution. Experimental validation optimized the retraction distance and electrolyte temperature which could improve machining rate and ensure hole accuracy. Ultimately, the holes of 75 mm deep were fabricated at 5.1 mm/min employing above two techniques for the first time, representing an enhancement of 112.5% on machining efficiency. And the maximum processing speed fabricating shallow holes reaches 7 mm/min which is increased by 16.7% compared to conventional LECM. Synergistic use of high temperature electrolytes and insulation layer retraction effectively breaking through the hole machining efficiency ceiling of LECM, furnishing a new method for micro hole fabrication in aero-engine components.