An overview on machinability of hard to cut materials using laser assisted machining

Bharat, Nikhil; Bose, P.S.C.

doi:10.1016/j.matpr.2020.12.587

Cited by 19 publications

(6 citation statements)

References 50 publications

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“…SR was discovered to have a substantial rising tendency with increasing current and pulse length. However, when the gap voltage increased, SR showed a changing tendency (Bharat and Bose, 2021;Gupta et al, 2022). Based on the experimental results, it is indicated that the key factors impacting the material removal rate are the pulse ON time and pulse current.…”

Section: Introductionmentioning

confidence: 94%

Optimization on the electrical discharge machining (EDM) process parameters of aged AA7075/TiC metal matrix composites

Rajendran,

Duraisamy,

Raj Rajendran

et al. 2023

Rev. metal.

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The need to optimize the process parameters in Electrical Discharge Machining (EDM) for aged AA7075 Metal Matrix Composites (AAMMCs) is evident as it impacts various aspects such as mechanical properties, tool wear, surface finish, integrity, precision, accuracy, process stability, process consistency, and cost-effectiveness. In this study, aluminium alloy AA7075 was chosen as the matrix material because of the need to enhance its mechanical properties. Titanium Carbide (TiC) was chosen as the reinforcing material owing to its superior mechanical properties. Therefore, TiC holds the capability to improve the mechanical attributes of AA7075. The selection of the stir cast method for the manufacturing of AA7075/TiC (0, 4, 8, 12, and 16 wt.%) was based on its ease of fabrication, ability to achieve a uniform distribution of reinforcements, reduced susceptibility to oxidation and porosity, and improved control over the microstructure. This AA7075/12wt.%TiC MMC underwent an aging process at 520 °C for 180 min and was subsequently cooled within the furnace environment. The density of the aged and non-aged AA7075/TiC-based composites was determined through a density test using the Archimedes’ principle. Microhardness testing was conducted on the non-aged and aged AA7075-based MMCs employing a Vickers microhardness tester. Tensile strength and compressive strength of the aged and non-aged AA7075-based MMCs were determined by the usage of a universal testing machine (UTM) and a compression testing machine (CTM). The optimal combination of the manufactured AA7075/TiC MMCs was determined based on their mechanical properties. The most effective combination was identified as AA7075/12wt.%TiC MMC due to its superior values in hardness, tensile strength, compressive strength, and density compared to other combinations. The aging process aimed to enhance the mechanical properties without the need for additional reinforcements. EDAX and X-ray Diffraction Analysis (XRD) tests were employed to determine the weight percentage of the matrix and reinforcements and to identify the formation of precipitates in the AA7075/12wt.%TiC composites. The SEM equipment was utilized to verify the uniform distribution of titanium carbide in the matrix material AA7075. Optimization of EDM process parameters for aged AA7075/12wt.%TiC composite was carried out using Taguchi design-based Grey Relational Analysis (GRA). The selected input parameters for the optimization included the chromium concentration (g×l-1), current (amps) and pulse-on time (µs). The response parameters chosen for optimization were surface roughness (SR) and tool wear rate (TWR). The sequence of influencing EDM input parameters is chromium concentration, pulse on time and current. The optimized EDM process parameters were 8 g×l-1 chromium concentration, 5 amps current and 240 µs pulse on time and the corresponding response were 0.198 TWR and 1.56 SR.

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Section: Introductionmentioning

confidence: 94%

Optimization on the electrical discharge machining (EDM) process parameters of aged AA7075/TiC metal matrix composites

Rajendran,

Duraisamy,

Raj Rajendran

et al. 2023

Rev. metal.

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“…Laser assisted grinding (LAG) has been studied in numerous metals and ceramic materials [11,21] but there has been a few study with fibre-reinforced ceramic matrix composites. Especially for laser-assisted grinding of ceramic matrix composites, there is little research literature on the subject.…”

Section: Introductionmentioning

confidence: 99%

Cutting performance and tool wear in laser-assisted grinding of SiC_f/SiC ceramic matrix composites

Kong

Liu

Hou

et al. 2022

Mater. Res. Express

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Ceramic matrix composites have high hardness, so their machining requires high grinding forces that cause severe wear of the grinding head. To investigate this problem, the present study investigated the cutting performance of conventional grinding (CG) and laser-assisted grinding (LAG) of SiCf/SiC ceramic matrix composites using electroplated diamond grinding heads. Firstly, a three-dimensional transient heat transfer model based on a Gaussian heat source was developed to observe the surface and internal temperature field distributions of SiCf/SiC ceramic matrix composites subjected to laser irradiation. Secondly, the effects of laser heating temperature on the workpiece surface on the grinding forces were analysed. It was found that the axial and feed grinding forces were more than 40% lower under LAG than CG due to the removal mechanism of the SiC matrix changing from brittle fracture to ductile fracture and the oxidation reactions occurred in the SiCf/SiC ceramic matrix composites. Thirdly, the material removal mechanism was analysed by observing the morphology of machined surfaces, which showed that ductile removal from the SiC matrix occurs during LAG. Finally, it is also founded that the mean height of exposed abrasive grains from machined surface was reduced by 1.02 μm, 12.52 μm in LAG and CG respectively. The forms of wear caused by abrasive grains were studied. Under CG, the abrasive grains mainly exhibit cleavage fractures; while under LAG, micro-abrasion is the main wear form.

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“…3 The laser machining process was one of the earliest processes which used a laser beam as a source for cutting the hard to cut material. 4 Laser-assisted cutting (LAC) is a nontraditional subtractive machining technique that makes use of the laser beams' thermal energy. A high-energy laser beam hits on the workpiece surface during cutting process.…”

Section: Introductionmentioning

confidence: 99%

Parametric assessment of surface behavior and the impact of heat in micro drilling of fiber laser machined AISI h13

Rubaiee

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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H13 is a tool steel with good strength to thermal cracking, and resistance to wear, and erosion. It is extensively employed in the manufacture of molds and dies. Because of its hardness, it is challenging to manufacture with traditional methods, and damages the surface during cutting, which lessens the effectiveness of components. Recently, laser cutting has become a possible method for achieving high rates of material removal. The use of laser cutting to manufacture complicated forms is a contemporary development in laser technique. The drilling on 0.44 mm thick H13 by 100 m fiber laser rays is highlighted in this study. Entropy using COPRAS is employed to optimize fiber laser settings for the drilled hole. Response surface analysis is utilized to determine correlation of fiber lasers process parameter and ANOVA validates the model. Further, ANN is used to predict the experimental results. In the current research, the laser’s output power, scanning speed, and duty cycle are all taken into account. The results of the tests revealed that laser power is the most important element affecting the quality of drilled holes. The optimum condition of COPRAS grade offers 4.27 µm of roughness, 89.89 µm of heat impacted zone, 139.595 µm of overcut, and 0.074113 mm of material removal rate. The observed and predicted figures are relatively near to each other, according to the experiments. The outcomes of the confirmation test (PO = 5 W, SOS = 10 mm/s, DC = 25%) demonstrate that optimal conditions provide greater surface precision than initial trails.

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An overview on machinability of hard to cut materials using laser assisted machining

Cited by 19 publications

References 50 publications

Optimization on the electrical discharge machining (EDM) process parameters of aged AA7075/TiC metal matrix composites

Optimization on the electrical discharge machining (EDM) process parameters of aged AA7075/TiC metal matrix composites

Cutting performance and tool wear in laser-assisted grinding of SiC_f/SiC ceramic matrix composites

Parametric assessment of surface behavior and the impact of heat in micro drilling of fiber laser machined AISI h13

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An overview on machinability of hard to cut materials using laser assisted machining

Cited by 19 publications

References 50 publications

Optimization on the electrical discharge machining (EDM) process parameters of aged AA7075/TiC metal matrix composites

Optimization on the electrical discharge machining (EDM) process parameters of aged AA7075/TiC metal matrix composites

Cutting performance and tool wear in laser-assisted grinding of SiCf/SiC ceramic matrix composites

Parametric assessment of surface behavior and the impact of heat in micro drilling of fiber laser machined AISI h13

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Cutting performance and tool wear in laser-assisted grinding of SiC_f/SiC ceramic matrix composites