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Journal of Manufacturing Science and Engineering | Volume 131 | Issue 5 | Research Paper
Research Papers

Thermal Modeling and Experimental Investigation for Laser Assisted Milling of Silicon Nitride Ceramics

[+] Author and Article Information
Xinwei Shen, Shuting Lei

Department of Industrial and Manufacturing Systems Engineering, Kansas State University, Manhattan, KS 66506

J. Manuf. Sci. Eng 131(5), 051007 (Sep 08, 2009) (10 pages) doi:10.1115/1.3184086 History: Received October 30, 2008; Revised June 24, 2009; Published September 08, 2009
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This study is motivated by the fact that temperature control is very important for the success of laser assisted milling. A transient three-dimensional thermal model is developed using finite element analysis for laser assisted milling (LAMill) of silicon nitride ceramics, and then validated through a series of experiments of laser assisted face milling. This study aims to explore the thermal characteristics in LAMill of silicon nitride ceramics and thus provide guidelines on parameter selection for future operations. In addition, heat generation associated with machining is considered, and the effects of laser power, feed, and cutting speed on temperature are investigated. Simulation results show that heat generation associated with machining can be neglected. Laser power is one critical parameter for successful operation of LAMill. Moreover, both feed and cutting speed can affect the operating temperatures by varying feed rate; however, once feed rate is fixed, they have a little impact on the operating temperatures.
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References

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Figures

Grahic Jump Location
+Temperature histories with Pl=300 W (Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, and tp=15 s)
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Temperature histories with Pl=300 W (Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, and tp=15 s)
Figure 10

Temperature histories with Pl=300 W (Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, and tp=15 s)

Grahic Jump Location
+Temperature histories with Pl=410 W (Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, and tp=12 s)
View Large  |  Save Figure  |  Download Slide (.ppt)
Temperature histories with Pl=410 W (Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, and tp=12 s)
Figure 11

Temperature histories with Pl=410 W (Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, and tp=12 s)

Grahic Jump Location
+Temperature histories with Pl=470 W (Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/mn, and tp=8 s)
View Large  |  Save Figure  |  Download Slide (.ppt)
Temperature histories with Pl=470 W (Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/mn, and tp=8 s)
Figure 12

Temperature histories with Pl=470 W (Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/mn, and tp=8 s)

Grahic Jump Location
+Temperature histories with f=0.012 mm/tooth/rev (Pl=410 W, Vc=1.0 m/s, Vf=3 mm/min, and tp=12 s)
View Large  |  Save Figure  |  Download Slide (.ppt)
Temperature histories with f=0.012 mm/tooth/rev (Pl=410 W, Vc=1.0 m/s, Vf=3 mm/min, and tp=12 s)
Figure 13

Temperature histories with f=0.012 mm/tooth/rev (Pl=410 W, Vc=1.0 m/s, Vf=3 mm/min, and tp=12 s)

Grahic Jump Location
+Temperature histories with f=0.048 mm/tooth/rev (Pl=410 W, Vc=1.0 m/s, Vf=12 mm/min, and tp=12 s)
View Large  |  Save Figure  |  Download Slide (.ppt)
Temperature histories with f=0.048 mm/tooth/rev (Pl=410 W, Vc=1.0 m/s, Vf=12 mm/min, and tp=12 s)
Figure 14

Temperature histories with f=0.048 mm/tooth/rev (Pl=410 W, Vc=1.0 m/s, Vf=12 mm/min, and tp=12 s)

Grahic Jump Location
+Schematic of laser assisted face milling
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Schematic of laser assisted face milling
Figure 1

Schematic of laser assisted face milling

Grahic Jump Location
+FEA model with one-half of the workpiece
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FEA model with one-half of the workpiece
Figure 2

FEA model with one-half of the workpiece

Grahic Jump Location
+Schematic of cutting zone in face milling
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Schematic of cutting zone in face milling
Figure 3

Schematic of cutting zone in face milling

Grahic Jump Location
+FEA mesh for the cutting zone
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FEA mesh for the cutting zone
Figure 4

FEA mesh for the cutting zone

Grahic Jump Location
+Experimental setup of laser assisted milling
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Experimental setup of laser assisted milling
Figure 5

Experimental setup of laser assisted milling

Grahic Jump Location
+Positions of laser spot and pyrometer spot
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Positions of laser spot and pyrometer spot
Figure 6

Positions of laser spot and pyrometer spot

Grahic Jump Location
+Temperature contours of the workpiece obtained from simulation (Pl=410 W, Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, tp=12 s, and Lc=7.0 mm)
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Temperature contours of the workpiece obtained from simulation (Pl=410 W, Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, tp=12 s, and Lc=7.0 mm)
Figure 7

Temperature contours of the workpiece obtained from simulation (Pl=410 W, Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, tp=12 s, and Lc=7.0 mm)

Grahic Jump Location
+Cutting zone and its temperatures: (left) cutting zone, (right) temperatures over the cutting zone obtained from simulation (Pl=410 W, Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, tp=12 s, and Lc=7.0 mm)
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Cutting zone and its temperatures: (left) cutting zone, (right) temperatures over the cutting zone obtained from simulation (Pl=410 W, Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, tp=12 s, and Lc=7.0 mm)
Figure 8

Cutting zone and its temperatures: (left) cutting zone, (right) temperatures over the cutting zone obtained from simulation (Pl=410 W, Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, tp=12 s, and Lc=7.0 mm)

Grahic Jump Location
+Temperature contours obtained on the back face from simulation (Pl=410 W, Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, tp=12 s, and Lc=7.0 mm)
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Temperature contours obtained on the back face from simulation (Pl=410 W, Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, tp=12 s, and Lc=7.0 mm)
Figure 9

Temperature contours obtained on the back face from simulation (Pl=410 W, Vc=1.0 m/s, f=0.024 mm/tooth/rev, Vf=6 mm/min, tp=12 s, and Lc=7.0 mm)

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