Optimization of surface roughness and tool wear in laser-assisted machining of alumina ceramics using Taguchi method

Abstract

To investigate the effects of laser power, cutting depth, feed, and spindle speed on the surface roughness of the workpiece and the wear of the back face, a one-factor experiment was first conducted to determine the selection range of the experimental parameters. Subsequently, an orthogonal experiment including four factors and four levels was designed using the Taguchi method to analyze in depth the machining process of laser heating-assisted turning of alumina (Al 2 O 3 ) ceramic materials with cubic boron nitride tools. Through analysis of variance and main effect analysis of each factor, the magnitude of each turning parameter on surface roughness and tool wear was determined, and the best combination was obtained. Conventional turning was carried out under the optimal cutting parameters, and the scanning electron microscope surface morphology of the workpiece under the two cutting conditions of laser-assisted machining and conventional machining was analyzed and compared. The results show that compared with conventional turning, the surface removal of laser heating-assisted turning is more thorough, the surface particle distribution is more uniform, and the surface integrity is significantly improved. In the appropriate range of cutting parameters, increasing the laser power and reducing the cutting depth can significantly reduce the surface roughness of the Al 2 O 3 workpiece. Under the optimal parameter combination, the surface roughness value is Ra ¼ 0.793 μm, and the reduction range is 56.33%. By increasing the laser power, reducing the spindle speed and cutting depth, the degree of tool wear is significantly reduced. The tool wear value under the optimal parameter combination is VB ¼ 58.4 μm., which is reduced by 62.7%.