Laser and arc manufacturing processes: A review

Lee, Choon-Man; Woo, Wan-Sik; Baek, Jong-Tae; Kim, Eun-Jung

doi:10.1007/s12541-016-0119-4

Cited by 48 publications

(8 citation statements)

References 107 publications

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“…Thermally assisted machining (TAM) methods have been proposed to enhance the machinability of these difficult-to-cut materials, in which a local heat source (e.g. laser beam, plasma beam [10]) is placed ahead of the cutting area to preheat the workpiece material locally and thereby reduce its strength during the machining process. With the rapid development of laser technology, laser assisted techniques now have many advantages over other pre-heating techniques, e.g.…”

Section: Introductionmentioning

confidence: 99%

On modelling of laser assisted machining: Forward and inverse problems for heat placement control

Shang

Liao

Sarasua

et al. 2019

International Journal of Machine Tools and Manufacture

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Laser assisted machining (LAM) is one of the most efficient ways to improve the machinability of difficultto-cut materials (e.g. Nickel-based superalloys). In the conventional LAM process, the laser beam is focused ahead of the cutting area at a fixed location, which leads to a series of restrictions, e.g. small heating area and non-uniform heat distribution due to the limitation of beam size and energy distribution. In this paper, a novel spatially and temporally (S&T) controlled laser heating method was proposed, in which a large area can be heated up with a small laser spot by controlling the beam scanning, i.e., laser power, path and speed of scanning. The laser configuration for the prescribed HAZ (heat affected zone) was achieved by solving the inverse problem where the laser power together with either laser path or laser speed were optimised to achieve a particular temperature distribution in the chip to be removed by the following milling cutter. The proposed S&T laser heating method was thoroughly validated both for the forward and, the more important, inverse heating models by performing extensive temperature experiments by both infrared thermal camera and thermocouple array and further verified by laser assisted milling (LAMill) tests of Inconel 718 for large widths of cuts. The results showed that by applying path-optimised LAMill based on the inverse solution of the thermal problem, the peak and mean principal cutting forces were reduced by 55% and 47.8% respectively compared with the conventional dry milling process while the surface roughness improved by at least 14%. Moreover, after controlling the HAZ using the inverse thermal problem, a microstructure analysis of the machined surface showed that the proposed laser heating method avoids overheating of the workpiece below the planned depth of cut for the milling operation.

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Section: Introductionmentioning

confidence: 99%

On modelling of laser assisted machining: Forward and inverse problems for heat placement control

Shang

Liao

Sarasua

et al. 2019

International Journal of Machine Tools and Manufacture

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“…Other studies suggested measuring the wear and the edge profile of the cutting tool using predicted or developed theoretical models, simulation software and edges scanned 2D images [25][26][27][28][29]. However, there are still some percentage difference and deviations values between the results gained by the theoretical models and the manufacturer data.…”

Section: Surface Profile Form Measurementsmentioning

confidence: 99%

Impact of work hardening, tool wear and geometry response on machinability during turning AL‐6XN super austenitic stainless steel: A work hardening and wear studies on AL‐6XN alloy

Alabdullah

Polishetty

Nomani

2017

Materialwissenschaft Werkst

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This work aimed to identify the work‐hardening regions in shear zones when the AL‐6XN super austenitic stainless steel alloy was machined using a turning machine. A quick‐stop approach was used to generate frozen chip roots. Two cutting speeds of 94 m/min and 65 m/min, a feed rate of 0.2 mm/rev and depth of cut of 1 mm were applied in this study. Microhardness measurements were executed in the hardening region (workpiece–shear zone–chip zone). Results showed that the hardness values were significantly increased in the primary shear zone and the formed chip. The wear of the cutting tool used to machine the alloy was investigated using scanning electron microscope. Excessive notch wear was located on the cutting edge when 65 m/min cutting speed was utilized while at 94 m/min cutting speed, the cutting edge was completely damaged as a flake of the edge was removed due to hard cutting processes. The profile measurement of the cutting tool was executed using an optical profilometer to reveal the changes in the cutting edges locations and profiles and their implication on machining process.

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“…A study was also conducted on the machining of brittle materials such as ceramics and glass [11,12,13,14]. Furthermore, hybrid processes that combine LAM and other processes have been proposed [15,16]. One TAM method, PAM, is more attractive commercially because it is lower in price than the LAM.…”

Section: Introductionmentioning

confidence: 99%

A Study on Optimal Machining Conditions and Energy Efficiency in Plasma Assisted Machining of Ti-6Al-4V

Lee

2019

Materials

Self Cite

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This research objective was to determine the significant parameters for effective plasma assisted machining (PAM) of Ti-6Al-4V and to derive optimal processing conditions. PAM parameters such as feed rate, spindle speed, and depth of cut have significant effects on its machining characteristic. In this study, the design of experiments (DOE) was used to select optimal machining conditions for PAM. The signal-to-noise (S/N) ratio was analyzed using the Taguchi method and the contributions of the factors were determined using analysis of variance (ANOVA). Finally, the optimal PAM machining conditions were selected using response optimization. In addition, the energy efficiency of conventional machining (CM) and the PAM were compared. The energy efficiency was analyzed by specific cutting energy. The cutting force and surface roughness of PAM decreased by 60.2% and 70.5%, respectively, in optimal PAM machining conditions.

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Laser and arc manufacturing processes: A review

Cited by 48 publications

References 107 publications

On modelling of laser assisted machining: Forward and inverse problems for heat placement control

On modelling of laser assisted machining: Forward and inverse problems for heat placement control

Impact of work hardening, tool wear and geometry response on machinability during turning AL‐6XN super austenitic stainless steel: A work hardening and wear studies on AL‐6XN alloy

A Study on Optimal Machining Conditions and Energy Efficiency in Plasma Assisted Machining of Ti-6Al-4V

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