Hybrid-hybrid turning of micro-SiCp/AA2124 composites: A comparative study of laser-and-ultrasonic vibration-assisted machining

Kim, Jin; Zani, Lorenzo; Abdul-Kadir, Ahmad; Roy, Anish; Baxevanakis, Konstantinos P.; Jones, Lewis C.R.; Silberschmidt, Vadim V.

doi:10.1016/j.jmapro.2022.12.045

Cited by 22 publications

(10 citation statements)

References 43 publications

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“…In most studies, tool life is extended, but improvement in surface quality after machining has only been observed in certain research endeavors. Kim et al [176,179] and Li et al [180] studied a distinct and unique machining process named laser and ultrasonic vibration-assisted machining (LUVAM), and its schematic is shown in figure 22(a). This process aims to enhance the machining performance of three types of micro-SiC/AA2124 composites.…”

Section: Hybrid Nontraditional Energy-assisted Turningmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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Difficult-to-cut materials such as titanium alloys, high-temperature alloys, metal/ceramic/polymer-matrix composites, hard and brittle materials, as well as geometrically complex components such as thin-walled structures, micro channels and complex surfaces, are widely used in aerospace community. Mechanical machining is the main material removal process and responsible for the vast majority of material removal for aerospace components. Nevertheless, it encounters many problems in terms of severe and rapid tool wear, low machining efficiency, and deteriorated surface integrity. Nontraditional energy-assisted mechanical machining is a hybrid process in which nontraditional energies, e.g., vibration, laser, electric, etc., are applied to improve the machinability of local material and decrease burden of mechanical machining. It provides a feasible and promising way for improving machinability and surface quality, reducing process forces, and prolonging tool life, etc. However, systematic reviews of this technology are lacking with respect to the current research status and development direction. This paper reviews recent progress in nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community. It focuses on the processing principles, material responses under nontraditional energy, resultant forces and temperatures, material removal mechanisms and applications of these processes including vibration-, laser-, electric-, magnetic-, chemical-, cryogenic cooling-, and hybrid nontraditional energies-assisted mechanical machining. Eventually, a comprehensive summary of the principles, advantages and limitations for each hybrid process is provided, and future perspectives on forward design, device development and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

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Section: Hybrid Nontraditional Energy-assisted Turningmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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“…The higher damage on the machined surface was observed during the UVLAT process than that of the CT process (figure 5) and the reason was explained in section 3.4 which corelates well with the surface roughness. Kim et al and Dominguez-Caballero et al also reported higher surface roughness during the UVLAT process when compared with the CT process [26,28]. According to them, higher machining temperature during the UVLAT process led to higher heat affected zone with severe thermal damage, resulting in higher damage on the machined surface and higher surface roughness for the UVLAT process than the CT process.…”

Section: Surface Roughnessmentioning

confidence: 99%

“…Moreover, the higher maximum machining temperature during the UVLAT process would have led to the more sticking of the particles on the cutting tool edge which could have ploughed on the machined surface, resulting in higher damage on the machined surface. Kim et al reported that the surface temperature of the workpiece increased which led to the higher heat affected zone with severe thermal damage and the thermal damage would have surpassed the machining depth of cut, resulting in higher damage on the machined surface [26]. They also indicated that careful assessment would be required before commencing any machining during the UVLAT process.…”

Section: Surface Damagementioning

confidence: 99%

“…Significant reduction in machining forces (31%-61%), increment in machining temperature (196%), and reduction in surface roughness (45%) were reported for the hybrid machining process than that in the CT process [25]. In another study, Kim et al analyzed tool wear and developed a numerical model to predict the machining stresses and machining temperature [26]. Wang et al modelled the ultrasonic vibration assisted laser processing on the aluminium surface and validate with the experiments to analyze the surface microstructure [27].…”

Section: Introductionmentioning

confidence: 99%

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Radial direction ultrasonic-vibration and laser assisted turning of Al3003 alloy

Deswal

Kant

2023

Mater. Res. Express

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The utilization of various energy sources to assist the machining process has become prominent to achieve substantial improvement in machining performance. These energy sources have also resulted in an alternative to cutting fluids which is safer for both the universe and human beings. The combined action of laser and ultrasonic vibration energies during the turning process has shown significant achievement in machining process capabilities. Therefore, an attempt has been made to provide ultrasonic vibration in the radial direction and laser to preheat aluminium 3003 alloy simultaneously during the ultrasonic-vibration-laser assisted turning (UVLAT) process. Machining performance has been analyzed in terms of machining forces, machining temperature, chip morphology, surface damage, and surface roughness. A comparative machining performance analysis has been carried out among the conventional turning (CT), laser assisted turning (LAT), ultrasonic vibration assisted turning (UVAT), and UVLAT processes. The outcomes of the current study indicate significant benefits of the UVLAT process on the machining performance of aluminium 3003 alloy. However, surface damage and surface roughness have been affected negatively during the UVLAT process due to the pin-point hammering and particle adhesion on the workpiece part. Hence, the selection of vibration direction is a critical factor during the vibration machining processes.

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“…Because of the advantages of high power density, adaptability, environmental protection, and high cost performance, laser beam has become an efficient processing tool with the rapid development of laser technology [6]. At the same time, laser-assisted machining (LAM) has been recognized as an alternative to traditional processing of cemented carbide or difficult-to-process materials [7][8]. LAM is to focus the highpower laser beam on the surface of the workpiece at a certain distance before the cutting path, and heat the local temperature to a very high temperature in a very short time before the material is cutting off.…”

Section: Introductionmentioning

confidence: 99%

Effect of laser abrasive belt processing on surface quality of titanium alloy TC17Effect of laser abrasive belt processing on surface quality of titanium alloy TC17

Liu

Deng

Xiao

et al. 2023

Preprint

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Due to its low thermal conductivity, work hardening and other characteristics, titanium alloys are prone to shortcomings such as large cutting force and poor processing quality in the processing process. Laser-assisted grinding (LAG) can significantly improve its processing performance, but the mechanism of synergistic parameters between laser and abrasive belt on surface quality has not been clearly revealed in the laser-assisted belt grinding process. Based on this, this paper proposes a method of laser-belt collaborative processing (LBCP), established a mathematical model of laser and abrasive belt co-processing, and reveals the collaborative processing mechanism. Through the LBCP experiment of titanium alloy TC17, the grinding force, surface morphology, and roughness of titanium alloy TC17 were investigated, and the effect of different collaborative processing factors on the surface quality of titanium alloy was studied. The results show that appropriately increasing the normal pressure will improve the surface quality of titanium alloy. The larger the laser incidence angle, the better the surface quality. Reducing the synergistic distance between the laser and the abrasive belt improves the surface quality. This study provides new ideas for laser-assisted processing of difficult-to-process materials.

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Hybrid-hybrid turning of micro-SiCp/AA2124 composites: A comparative study of laser-and-ultrasonic vibration-assisted machining

Cited by 22 publications

References 43 publications

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Radial direction ultrasonic-vibration and laser assisted turning of Al3003 alloy

Effect of laser abrasive belt processing on surface quality of titanium alloy TC17Effect of laser abrasive belt processing on surface quality of titanium alloy TC17

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