Conceptualization of a Hybrid Machine Combining Laser Beam Micro Machining (LBMM) and Micro Electrical Discharge Machining (Micro-EDM) in a Single Setup

The utilization of hybrid laser beam micromachining (LBMM) in conjunction with micro electrical discharge machining (mu EDM) has gained widespread popularity due to its ability to improve material removal rates and enhance surface quality. Typically, these processes occur on separate machines, resulting in drawbacks such as time loss during workpiece transfer, potential misalignment issues, and increased risks of sample damage during the transfer. This research provides a system and method for a two-step sequential machining process of LBMM and mu EDM that allows the workpiece to remain at the same location for both processes. A LBMM process is used for drilling a rough blind hole, followed by mu EDM for the finishing process. The workpiece is fixed and positioned in the mu EDM workstation. A microscopic camera, which is mounted on the mu EDM machine, is used to provide common coordinate position data for the laser and mu EDM machine. This coordinate is used by the mu EDM machine to position the electrode perfectly on top of LBMM hole before machining. The results suggest that LBMM-mu EDM machining can reduce machining time while achieving good hole quality and repeatability. The hybrid sequential process significantly reduces drilling time, being about 1.55 times faster than the pure mu EDM method. However, the findings also indicate that it is not necessary to use LBMM-mu EDM for low aspect ratio holes. This concept enables the workpiece to stay in one position throughout both processes, eliminating any time loss and damage during transfer, as well as avoiding misalignment issues.