Process energy analysis for aluminium alloy and stainless steel in laser-assisted jet electrochemical machining

Laser-assisted jet electrochemical machining (LAJECM) is a hybrid process that combines a relatively low-power laser beam (typically 375 mW) with an electrolyte jet to facilitate metal removal. The main purpose of the laser is to enhance the localization effect of electrochemical dissolution from the workpiece, thus giving better precision and efficiency. The laser thermally activates the material surface where it impinges, thereby increasing the electrochemical current density in that localized zone. This paper reports recent investigations of LAJECM process energy distribution and explains the influence of laser assistance on dissolution removal rates using theoretical as well as experimental analysis. It was found that laser assistance increases energy in the LAJECM process by up to 45 per cent compared with jet electrochemical machining (JECM). The process energy has also been related to volumetric removal rate, and the specific energy required for machining with given variables has been calculated. It has been proved that LAJECM is more effective then JECM as the calculated specific energy was lower by up to 30 per cent.