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Research Papers

Laser-Assisted Milling of Silicon Nitride Ceramics and Inconel 718

[+] Author and Article Information
Yinggang Tian, Benxin Wu, Mark Anderson, Yung C. Shin

Center for Laser-Based Manufacturing, Purdue University, West Lafayette, IN 47907

J. Manuf. Sci. Eng 130(3), 031013 (Jun 03, 2008) (9 pages) doi:10.1115/1.2927447 History: Received February 08, 2007; Revised March 06, 2008; Published June 03, 2008

Laser-assisted machining (LAM) has shown its potential to significantly reduce fabrication costs and improve product quality for advanced materials. While extensive studies have been conducted on laser-assisted turning of various ceramics and high temperature alloys, few attempts have been made to extend LAM to milling operations. In this paper, a transient, three-dimensional thermal model developed for laser-assisted milling (LAML) is presented and its accuracy is verified by surface temperature measurements with an infrared camera. LAML experiments designed by the model are successfully conducted on silicon nitride ceramics using TiAlN coated carbide end mills and Inconel 718 using SiC reinforced alumina cutting tools. The promising experimental results, including good surface roughness and acceptable tool wear, show the validation of applying the thermal model to design LAML processes and the feasibility of employing LAML for difficult-to-machine materials such as advanced ceramics and superalloys.

Copyright © 2008 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Sketch of the modeled LAML

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Figure 2

The heat flux into a mesh cell

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Figure 3

Schematic of the LAML setup

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Figure 4

Schematic of the laser heating setup (a) for prismatic model with (b) thermocouple locations on the workpiece with respect to laser heating track.

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Figure 5

Sketch of the experimental setups for the LAML of silicon nitride

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Figure 6

Predicted temperatures compared to IR camera measurements for Heating1

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Figure 7

Predicted Tmax compared to IR camera measurements for Si3N4 workpiece

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Figure 8

Predicted temperatures compared to thermocouple measurements for Inconel 718 workpiece

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Figure 9

Optical micrograph of a section view for a workpiece produced by LAML2

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Figure 10

Flank wear of the TiAlN coated carbide tools after 20mm cutting of LAML

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Figure 11

Flank wear of the TiAlN coated carbide tools after 60mm cutting of LAML

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Figure 12

Flank wear of the TiAlN coated carbide tools during LAML of silicon nitride

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Figure 13

Average surface roughness of the silicon nitride workpiece made by LAML

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Figure 14

Average maximum measured forces along the X, Y, and Z directions

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Figure 15

Measured cutting forces as a function of machining time at V=6.76m∕s, fr=0.0125mm∕rev, Tmr=400°C (INM1, INM2)

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Figure 16

Tool wear on the SiC reinforced alumina insert after machining 20mm Inconel 718

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Figure 17

Nose of the SiC reinforced alumina insert after 9s of machining time for Inconel 718 (a) conventional machining and various Tmr experiments: (b) Tmr=400°C, (c) Tmr=520°C, and (d) Tmr=1200°C

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Figure 18

Average surface roughness as a function of laser power during milling of Inconel 718

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