Bore holes with a high length-to-diameter (l/D)-ratio and small diameters are needed in various industries. Examples are the downsizing of components for medical and biomedical products or for fuel injection in automotive industry due to the increase of injection pressure. For the production of deep holes with very small diameters an adapted process design is necessary, especially when the conditions at the begin of the deep hole drilling process are unfavorable. In these applications, a hybrid process consisting of a laser pre-drilling and a single-lip deep hole drilling can shorten the process chain in machining components with non-planar surfaces, or can reduce tool wear in machining case-hardened materials. In this research, the combination of laser and single-lip drilling processes for the machining of workpieces with non-planar surfaces was realized and investigated for the very first time.

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