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Laser-Assisted Machining of Ti-6Al-4V Fabricated by DED Additive Manufacturing
摘要： Recently, the commercialization of hybrid machine tools that combine directed energy deposition (DED) additive manufacturing (AM) technology and subtractive manufacturing (SM) has rapidly progressed. This technology trend has been developed to meet the market demand for processing quality (precision) and productivity, and to produce products such as lightweight parts, and complex and special functional parts, as well as to facilitate mold production and part repair. Compared to SM technology, metal AM technology has limitations in terms of surface quality and shape accuracy. Therefore, post-processing is necessary for the AM output. Laser-assisted machining (LAM) is an innovative hybrid technique in which surface quality and productivity can be improved by enhancing the machinability of difficult-to-cut materials. LAM studies have mainly been performed on titanium alloys, nickel based alloys and ceramic materials. However, except for ceramics, no high-strength material studies have been conducted to analyze the LAM process machining characteristics of workpieces fabricated by AM process. Therefore, in this study, LAM is applied to post-processing of output fabricated by AM of Ti-6Al-4V. DED device was developed using metal powder feeder and a laser. The Ti-6Al-4V workpieces were successfully fabricated through many tests. The cutting depth for LAM was selected through thermal analysis for LAM of the fabricated workpiece. Compared to the case of traditional machining without preheating, machining characteristics in LAM experiments were analyzed and property testing was performed.
关键词： Machining characteristics,Additive manufacturing,Directed energy deposition,Ti-6Al-4V,Laser-assisted machining
更新于2025-09-23 15:19:57
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Low power direct laser-assisted machining of carbon fibre-reinforced polymer
摘要： The direct laser-assisted machining (DLAM) technique is introduced to improve the CFRP machining process. The DLAM technique applies focused laser at the tool edge through a sapphire tool. A fibre laser with 4.3 W power was used to have the desired temperature, estimated from the finite element model. Experimental orthogonal cutting tests were performed to compare the DLAM technique to the conventional dry cutting of the woven CFRP. We have observed reduced cutting forces in both in-plane and side cutting orientations. Observations with 3D surface profilometer also showed a decrease in defects and improved surface roughness when DLAM was applied.
关键词： CFRP machining,thermo-mechanical properties,Laser assisted machining
更新于2025-09-19 17:13:59
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Preheating and thermal behaviour of a rotating cylindrical workpiece in laser-assisted machining
摘要： Laser-assisted machining is a widely used technique for preheating workpiece to reduce cutting forces and promote machinability in metal machining, thereby enhancing manufacturing quality and productivity. In setting laser-assisted machining parameters, the current practice typically relies on trial-and-error approaches. The uncertainties thereof could lead to adverse outcomes in product manufacturing, thus negating the potential benefits of this machining method. A clear understanding of workpiece thermal behaviour under laser spot heating is pivotal to developing a systematic basis for determining required preheating levels and optimised cutting variables for laser-assisted machining. In achieving this, the experimental methods are recognised to be largely impractical, if not tedious, due to instrument limitations and practicality of suitable non-intrusive measuring methods. Conversely, numerical methodologies do provide precise, flexible and cost-effective analytical options, warranting potential for insightful understanding on the transient thermal impact from laser preheating on rotating workpiece. Presenting such an investigation, this article presents a finite volume-based numerical simulation that examines and analyses the thermal response imparted by laser spot preheating on a rotating cylinder surface. On a rotating frame of reference using the ANSYS Fluent solver, the numerical model is formulated, accounting for transient heat conduction into the cylinder body and the combined convection and radiation loses from the cylinder surface. The model is comprehensively validated to ascertaining its high predictive accuracy and the applicability under reported laser-assisted machining operating conditions. The extensive parametric analyses carried out deliver clear insight into the dynamics of thermal penetration occurring within the workpiece due to laser spot pre-heating. This facilitates appropriate consideration of laser preheating intensity in relation to other operating variables to achieve necessary material softening depth at the workpiece surface prior to setting out on the subsequent machining process. Building upon the data generated, a practically simpler and cost-effective preheating parametric predictor is synthesised for laser-assisted machining using neural network principles incorporating the Levenberg–Marquardt algorithm. This predictive tool is trained and verified as a practical preheating guide for laser-assisted machining for a range of operating conditions.
关键词： numerical thermal modelling,Laser-assisted machining,artificial neural network,validation,thermal treatment
更新于2025-09-19 17:13:59
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High Speed Machining || Laser-assisted high speed machining of Inconel 718 alloy
摘要： The material is termed as hard-to-machine if it possesses any of the following properties, such as higher toughness, increased resistance to corrosion and fatigue, low thermal conductivity, high hardness and brittleness, and high strength to weight ratio. On extreme machining conditions these characteristics lead to increased tool wear, higher heat generation, increased cutting energy, poor surface finish, and difficulty in chip formation. Hard-to-machine materials are classified into three broad categories: hard materials, nonhomogeneous materials, and ductile materials as shown in Fig. 9.1. The reason for considering hard material as hard-to-machine material is because of the higher strength, hardness along with poor thermal conductivity that would end up in shorter tool life, poor surface quality, and lower productivity. Because of high ductility, strain rate, and nonuniform chip formation, the materials like low carbon steels, polymers, etc., are also categorized as hard-to-machine material. The nonhomogenous material distribution present in the composite material makes it hard-to-machine that results in lesser tool life and poor surface finish [1].
关键词： hybrid machining,Inconel 718,high speed machining,Laser-assisted machining,hard-to-machine materials
更新于2025-09-16 10:30:52
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A study on preheating temperature and heat affected depth according to various laser beam angle for laser-assisted machining
摘要： Laser-assisted machining (LAM) is a new method and actively researched for various difficult to machine materials. In LAM, machining is carried after prediction of material removal temperature (preheating temperature) for material with fixed cutting depth using a laser source. Among the various difficult-to-cut materials, Inconel 718, nickel-based super alloys, is difficult to machine due high strength at elevated temperature and low thermal conductivity. Studies on machining of Inconel 718 using a laser has been performed for various position of laser source to reveal the process benefits of Inconel 718 with fixed cutting depth. But there are no studies and results on prediction of heat affected depth for preheating temperature using laser assisted machining of Inconel 718 on various laser beam angle. So, in the present study, the effect of application of laser when applied at different angles is studied by two different methods- one with offset and other without offset. Finite element method is used to perform the simulations. This contribution brings a new novelty to the present research work on metal cutting domain using laser. The heat affected depth was also found and compared with depth obtained through experiments. And, the error percentage found for heat affected depth and preheating temperature is about 11%. The experimental results reveal that laser beam at an angle of 60° has maximum depth of cut, while minimum depth of cut is found at 90°.
关键词： laser beam angle,laser-assisted machining,heat affected depth,preheating temperature
更新于2025-09-16 10:30:52
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Effects of Preheating Temperature at Primary Shear Zone in Laser Assisted Milling Process
摘要： In this paper, preheating temperature was investigated for the laser assisted machining (LAM) of Inconel 718 under different conditions for the milling test. The experimental results show that the requirement of laser power for the particularly preheating temperature proportionally increased with the table speed. The resultant cutting force for sufficient shearing work material in LAM was lower than conventional machining (CM) approximately 11, 21 and 28% for the cutting speed of 30, 50 and 75 m/min, respectively. The tool wear in LAM could be improved at relatively high cutting speed of 75 m/min and the hardness of machined surface in LAM was slightly higher than CM.
关键词： Laser assisted machining,Milling,Inconel 718,Preheating temperature
更新于2025-09-16 10:30:52
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Modern Manufacturing Processes || Laser-assisted Machining Operations
摘要： There is a growing interest in the industry in improving productivity in manufacturing processes of materials with low machinability properties. Some high added value applications need manufacturing of parts with very high standards that cannot be satisfied with regular materials. Typically, these materials present high mechanical and thermal resistance combined with low thermal conductivity. The high shear strength makes difficult the plastic deformation during machining, and the low thermal conductivity affects directly tool life increasing the tool wear.
关键词： Laser-assisted machining,heat-assisted processes,direct laser machining,plasma-assisted machining,material machinability,thermal modeling
更新于2025-09-12 10:27:22
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Finite Element Simulation and Experimental Validation of Laser Assisted Machining of Inconel 718
摘要： Laser assisted machining (LAM) is a promising technology for machining of difficult to cut materials with reduced cutting forces, improved surface finish and tool life. This paper is mainly focused on study of cutting forces during laser assisted machining of Inconel 718 superalloy using finite element (FE) approach. An iterative procedure was adopted in this work to determine the coefficient of friction at tool chip interface to obtain rational values of cutting force for the identified cutting range. Arbitrary Lagrangian Eulerian (ALE) formulation was included to simulate the chip formation process. Johnson-cook material model for flow stress behaviour of workpiece material was incorporated during simulation. To validate the FE model, LAM experimentations were done under orthogonal cutting condition. The experiments were conducted according to Taguchi’s design of experiments. The cutting force results obtained through experimentation and simulation were compared and presented here. The FE prediction of cutting forces agrees with the experimental conditions for most of the cases within 15% deviation.
关键词： Cutting force,Finite Element Analysis,Inconel 718,Taguchi method,Orthogonal machining,Laser assisted machining
更新于2025-09-12 10:27:22
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Recent trends in laser assisted machining of ceramic materials
摘要： Machining of ceramics is difficult by conventional processes due to their hard and brittle nature as well as high costs involved. To overcome these disadvantages laser assisted machining (LAM) technique has been proposed. LAM has many advantages over conventional machining processes. LAM involves the use of a concentric beam of laser to heat and soften the work-piece thereby reducing its yield strength and increasing ease of machinability. With the progress of technology, numerous experiments involving LAM of ceramics have been performed and the effects of different machining parameters have been studied. In recent times, there have been various developments in laser technology, tools used and mechanisms of machining. This paper is intended to provide the elaborate literature review on the studies undergoing in LAM of ceramics and their comparison with conventional machining processes.
关键词： Laser assisted machining (LAM),tool life,laser,surface temperature,ceramics
更新于2025-09-12 10:27:22
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Prediction of surface roughness and material removal rate in laser assisted turning of aluminium oxide using fuzzy logic
摘要： Processing of ceramics with good surface integrity and high material removal rate is a challenging task in the manufacturing industry. Laser assisted machining (LAM) is one of the benchmark technique currently used in industry to process difficult to machine materials. In LAM, laser is used as source to heat the work piece and simultaneously remove the softened material by cutting tool without changing the material microstructure. Since many process parameters are involved in LAM, experimental investigation of processing of ceramics is expensive. So the main objective of this present work is to develop an Artificial Intelligence model to understand the process mechanics and for the prediction of surface roughness and material removal rate (MRR) during laser assisted turning of Aluminium oxide using fuzzy logic. Input parameters are assumed as triangular and Gaussian function and output parameters are assumed as trapezoidal function. It is inferred that increase in cutting speed and pulsed frequency of laser, there is an improvement in surface finish, whereas increase of feed rate results in deterioration of surface integrity. The material removal rate is directly proportional to feed, speed, depth of cut and pulsed frequency of laser. There is a better agreement between experimental and fuzzy model values. The proposed model predicts the surface roughness and MRR with prediction error of 15.76 and 7.69 % respectively.
关键词： material removal rate,Laser assisted machining,fuzzy logic,surface roughness,Ceramics
更新于2025-09-12 10:27:22