Application of laser and electrochemical interaction in sequential and hybrid micromachining processes

One of the research and development trends in nowadays manufacturing technology is integration of different manufacturing techniques into single machine tool. In the first part of the paper possibilities, goals, reasons and advantages of thermal and electrochemical interaction have been characterized. As literature review indicates such a connection can be realized as sequential or hybrid machining. The second part of the paper focuses on detailed analysis of laser assisted electrochemical process. For this purpose, the mathematical model of workpiece heating has been developed. Based on obtained results and literature review possibilities of technical realization and potential application have been discussed

Electrochemical intensification of microcutting process

W artykule przedstawiono koncepcję elektrochemicznej intensyfikacji procesu mikroskrawania. Wprowadzenie oddziaływań elektrochemicznych w warstwie powierzchniowej przedmiotu obrabianego umożliwia zmniejszenie wytrzymałości oraz twardości usuwanego materiału, co w efekcie powoduje obniżenie sił skrawania i zmniejszenie deformacji narzędzia oraz przedmiotu obrabianego. Prowadzi to do poprawy wskaźników technologicznych obróbki, umożliwiając rozszerzenie operacji mikroobróbki mechanicznej na wykonywanie struktur 3D m.in. operacjami mikrotoczenia, mikrowiercenia czy mikrofrezowania.In group of methods worked out for machining technological equipment, MEMS parts, functional prototypes and tools for micro-casting and micro-forming special attention is paid for application of microcutting and unconventional processes. The recent development is focused on 3D-shaped surfaces manufacturing. In case of microcutting the main problem during machining is connected with size effect. Significant forces in machining area limit microcutting process application to machine 3D parts made of soft materials and dimensions > 50 žm. One of effective methods to overcome these problems and achieves high performance for micromachining process is combining various physical and chemical processes into one machining process, defined as hybrid machining. One of the possibilities to decrease cutting forces is to decrease the mechanical properties by workpiece surface layer electrochemical passivation before or during cutting process. Between workpiece and additional electrode the electrolyte is supplied. When electrolyte pH and voltage are properly selected on the workpiece surface the thin oxide layer occurs. This layer is fragile and softer than core material, so can be easily removed with relatively smaller cutting forces, what increases tool life, decrease probability of tool damage, and increase accuracy of shaping by decreasing tool and workpiece deformation