Computerized Optimization of the Process Parameters in Laser-Assisted Milling

Wiedenmann, R.; Langhorst, Mirko; Zaeh, Michael F.

doi:10.1016/j.phpro.2011.03.077

Cited by 12 publications

(12 citation statements)

References 3 publications

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“…Material removal was enabled, and conduction, convection, and radiation of the material were all considered. It is known from other work [20] that conduction plays the most important role in modeling the LAML process, but convection and radiation were included, since it did not significantly affect computational time. An example of temperature prediction output from the thermal model is shown in Fig.…”

Section: Thermal Modelmentioning

confidence: 99%

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Laser-assisted milling of Ti-6Al-4V with the consideration of surface integrity

Hedberg

Shin

Liangji

2015

Int J Adv Manuf Technol

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Titanium alloys are well known for their excellent strength-to-weight ratio and corrosion resistance and is highly sought after in the aerospace industry. This study focused on experimental evaluation of laser-assisted milling (LAML) of a Ti-6AL-4V (Ti-64) workpiece which uses localized preheating of the workpiece by a laser and characterizes the improvements to the machinability of these metals. The benefits of LAML are quantified for laser parameters which are shown to maintain final surface integrity of the heat-treatable workpiece after the machining process. Laser parameters are determined based on temperature prediction modeling. Laser preheating is shown to reduce cutting force during the machining process. Machinability improvement is characterized through inspection of flank wear on the cutting tool using LAML and traditional machining methods and comparing total tool life. Systematic characterization of samples is performed using hardness measurements, scanning electron microscopy (SEM), and X-ray diffraction (XRD) to ensure that material properties remained unaltered as a result of laser preheating. An economic analysis is performed for LAML to characterize the improvement obtained despite the additional costs associated with the laser equipment.

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Section: Thermal Modelmentioning

confidence: 99%

“…Wiedenmann et al [20,21] presented temperature prediction work and experimental testing using a laser-assisted face milling setup. Modeling work was used to predict temperatures within the workpiece during the LAML process for a Ti-64 alloy.…”

Section: Introductionmentioning

confidence: 99%

Laser-assisted milling of Ti-6Al-4V with the consideration of surface integrity

Hedberg

Shin

Liangji

2015

Int J Adv Manuf Technol

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“…Since milling is an interrupted process with continual rotation of the cutter, there are some potential challenges in implementing laser assisted milling. Some recent studies have shown successful results of laser-assisted milling in micro scale [19][20][21] and macro scale [22][23][24][25][26][27]. Shelton et al [19,20] carried out laser assisted micro-milling on difficult-to-machine materials of AISI 316, AISI 422, Ti-6Al-4V and Inconel 718 using side milling and slotting configurations.…”

Section: Introductionmentioning

confidence: 99%

“…Tian et al [22], Yang et al [23] and Wiedenmann et al [24,25] presented modeling of temperature prediction during laser-assisted milling, which was subsequently used to design the process and determine the heat-affected zone. Ding et al [21] performed the combined thermal and mechanical modeling during laser assisted micro-milling of 422 SS, Inconel 718, and Ti-6Al-4V with a good experimental validation of the simulation results.…”

Section: Introductionmentioning

confidence: 99%

“…Modeling work is used to determine the temperature distribution during laser-assisted milling to design suitable operating parameters. Although similar modeling was performed to predict when a heat affected zone will appear on the workpiece surface [23,24], the current modeling work focuses on determining laser parameters that will avoid such damage and characterizing the potential benefits of LAML. A detailed surface integrity analysis is performed on the machined workpiece to determine the influence of laser parameters on final part properties.…”

Section: Introductionmentioning

confidence: 99%

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Laser Assisted Milling of Ti-6Al-4V ELI with the Analysis of Surface Integrity and its Economics

Hedberg

Shin

2015

Lasers Manuf. Mater. Process.

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This study presents the experimental evaluation of laser assisted milling (LAML) of Ti-6AL-4V ELI (Ti-64), which is used in the orthopedic industry, by using localized preheating of the workpiece via laser irradiation. Improvements to the machinability of this material with LAML are assessed while considering the surface integrity. Suitable laser heating conditions as well as machining conditions are determined based on temperature prediction modeling. Machinability improvements are shown in terms of tool wear, material removal rates and cutting force reduction. Systematic characterization of samples is shown to demonstrate that the machined sub-surfaces are not adversely affected during LAML by precisely controlling laser heating, via hardness measurements, scanning electron microscopy (SEM) for microstructure analysis, and X-ray diffraction (XRD) for residual stresses. An economic analysis shows that LAML provides the cost reduction over conventional machining.

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