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Research Papers

Experimental Evaluation of Laser-Assisted Micromilling in a Slotting Configuration

[+] Author and Article Information
Jonathan A. Shelton, Yung C. Shin

Center for Laser Based Manufacturing, School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907

J. Manuf. Sci. Eng 132(2), 021008 (Mar 31, 2010) (9 pages) doi:10.1115/1.4001142 History: Received January 13, 2009; Revised January 26, 2010; Published March 31, 2010; Online March 31, 2010

Micromilling can be difficult to apply to many engineering materials due to a variety of scaling induced factors including low cutting speeds, high relative tool deflections and runout, and increased material strength at smaller size scales. To alleviate these problems, laser-assisted micromilling (LAMM) was evaluated on Ti6Al4V, AISI 422, and AISI 316 using 100μm diameter endmills in slotting operations. A three-dimensional transient finite-volume based thermal model was used to analytically predict appropriate process parameters on the basis of material removal temperatures. A two-dimensional finite element model was created and used to show the effects of cutting edge radius, uncut chip thickness, and material removal temperature on the cutting force. A thorough experimental investigation of acoustic emissions (AEs) during LAMM was performed. In particular, the effects of depth of cut, tool wear, and material removal temperature on the root-mean-square of AEs were studied. The effects of LAMM on the machined surface finish and edge burrs were also evaluated.

Copyright © 2010 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Experimental setup for LAMM

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Figure 2

Conventionally micromilled 15 (wide)×90 (tall)×1500 (long) μm fins in 316SS

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Figure 3

Experimental setup for thermal paint absorptivity experiment showing laser alignment, travel direction, and painted surface (top)

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Figure 4

Isotherms in 534°C paint corresponding to a jump in laser power equivalent to a change in α of only 11%

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Figure 5

Example of 482°C and 371°C analytical isotherm locations

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Figure 6

Thermal paint experimental and finite-volume results (lines) for 316SS

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Figure 7

Thermal paint results for TI-64

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Figure 8

Image of laser and tool alignment marks

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Figure 9

Tp and Tmr versus absorbed laser power for 316SS and TI-64 at Ls=200 μm

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Figure 10

SEM measurement of Re on a new 100 μm tool

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Figure 11

Thermal initial and boundary conditions

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Figure 12

Initial mesh and workpiece deformation for 316SS after a 15 μm length of cut

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Figure 13

Transient cutting forces for TI-64

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Figure 14

Steady state, total specific cutting force versus Tmr at various values of tc for TI-64

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Figure 15

Steady state, total specific cutting force versus Tmr at various values of Re

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Figure 16

Steady state, total specific cutting force versus Tmr at various values of V

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Figure 17

Steady state, total specific cutting force for 316SS and TI-64 at values of tc and Tmr representative of experimental work

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Figure 18

AErms versus axial DOC for conventional (Tmr=20°C) for the materials and feedrates noted

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Figure 19

AErms versus number of tool cutting revolutions for 316SS at a constant axial DOC of 10 μm and the feedrates noted

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Figure 20

Average AErms values for slots in 316SS at 10 μm DOC

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Figure 21

Average AErms values for slots in TI-64 at 10 μm DOC

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Figure 22

AErms versus dimensionless time for 4 mm long slots in 316SS at a feedrate of 50 mm/min and 10 μm DOC

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Figure 23

Percent drop in AErms (experimental) and thrust force (FEM) for 316SS and TI-64

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Figure 24

Ra values for various feedrates and materials at 10 μm DOC

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Figure 25

SEM images of 316SS machined surfaces at 50 mm/min and 10 μm DOC. Conventional Ra=0.38 μm (left) and LAMM (Tmr=437°C)Ra=0.24 μm (right).

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Figure 26

422SS edge burrs on conventional (left) and LAMM (right) slots

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