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Machinability of titanium alloy through laser machining: material removal and surface roughness analysis
摘要： Laser milling is a competent precision process especially when the work material is hard-to-machine such as titanium alloys. While performing the laser milling, a slight change in one of the laser parameters results in an abrupt change in the machining outcomes. A close match between the designed and the machined geometries is the essence of precision machining. A precise control over the material removal rate per laser scan is highly desirable but difficult to achieve. The difficulty level becomes higher if high surface finish is desired alongside the precision machining. In this research, the objective was set to perform the laser milling on titanium alloy (Ti-6Al-4V) with 100% control over material removal rate (MRR) per laser scan and minimum surface roughness (SR). Influence of the five laser parameters (laser intensity, pulse frequency, scan speed, layer thickness, and track displacement) on MRR and SR has been deeply investigated. Significance of each laser parameter is evaluated through ANOVA. Mathematical models for both the responses are developed to estimate the resulting responses at any parametric setting. Models have also been validated through confirmatory tests. Optimization of laser parameters is of great importance to remove the material exactly equal to the desired depth with minimum surface roughness. Therefore, the optimized combinations of laser parameters have been proposed which ensure the conformance of 100% MRR and minimum surface roughness with composite desirability > 0.9. Confirmatory experiments revealed that the optimized parameters are capable to produce the laser milling results as per the models’ predicted results. Additionally, the microstructure of the subsequent layers below the milled area has also been examined and compared with the microstructure of the bulk Ti-6Al-4V. By the use of optimized parameters, microstructure of the sub-layers remains unchanged as compared with the microstructure of the base metal. No evidence has been found altering the microstructure of the sub-layers.
关键词： Laser milling,Titanium alloy,Mathematical model,Surface roughness (SR),Optimization,Material removal rate (MRR)
更新于2025-09-16 10:30:52
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Analysis of Thermal Stress and Temperature Distribution of Laser Power 10.0w and 20.0w on Material Removal in Aluminium Oxide Ceramic
摘要： The momentum look into researches the thermal stress investigation and temperature distribution of laser power 10.0w and 20.0w in aluminum oxide ceramic. Additionally, this paper explores the impact of thermal stress analysis and temperature distribution on material removal prepare. At the point when laser is connected for machining process for making smaller scale groove, temperature distribution assumes an imperative part for that since large amount of heat release by the laser which is influenced the material and deliver a heat affected zone thus material gets melted and vaporize. Thermal Stress is likewise being done because of nearness of thermal impact in material at the time of heat generation and it additionally assumes a decent part to achieve the great material removal handle. Accomplishing a fancied score of particular measurements is conceivable by having control over process parameters of a laser grooving machine which thus represents the measure of material removed. To handle with this, and concentrating on current trend where laser machining is exceptionally Demanded and connected in industry like like bio medical engineering, aerospace, automobile etc., and so on., it is particularly fundamental to concentrate the temperature distribution in the heat affected zone of the material where heat is created (due to heat energy released by laser beam) and equivalent thermal stress in the material body that is in charge of material removal, Achieving a desired groove with great precision. Limited component examination technique utilizing ANSYS is utilized to to simulate and analyze this temperature distribution and equivalent thermal stress of different laser power. In this paper temperature distribution FEM chart with diagrams for 10.0W and 20.0W, Material removal for 10.0W, 20.0W, Equivalent stress FEM diagram with graph for 100W, 200W are appeared furthermore the correlation of laser power in the vicinity of 10.0w and 20.0w are available.
关键词： Temperature Distribution,ANSYS,Laser Power,Material Removal,Thermal Stress
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
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State of the Art on Laser Assisted Electrochemical Machining
摘要： Laser Assisted Electrochemical Machining (LAECM) has proven its advantages and applications over almost all the range of conductive materials. It offers its adroitness to generate simple shapes to complex shapes from macro to micro machining. Laser assisted ECM is a hybrid approach of machining which has been manifested to obtain improved results in terms of surface integrity, thermal damage, geometrical tolerance and material removal rate. Laser assisted Electrochemical Machining (LAECM) is a hybrid machining process in which laser enhances the electrochemical dissolution process by increasing the temperature and hence the current density of the electrolyte. Laser helps to remove material from the particular machining zone and stray machining effect is reduced and thus improves the precision and efficiency of LAECM, also productivity. New route of laser assisted hybrid machining processes has been built in the past decade by few of the researchers to reduce the intrinsic problems of ECM. This paper reviews on the investigation into LAECM process. The article also highlights various possibilities and applications of LAECM process. There are various challenges in LAECM process which have been also discussed in this paper.
关键词： Laser Assisted Electrochemical Machining,electrochemical dissolution,material removal rate,LAECM,hybrid machining
更新于2025-09-12 10:27:22
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Performance evaluation and multi-response optimization of grinding-aided electrochemical discharge drilling (G-ECDD) of borosilicate glass
摘要： Machining of advanced glass ceramics is of great importance and is a challenging task for the modern industries. In this study, a new hybrid technique of grinding-aided electrochemical discharge drilling (G-ECDD) is attempted which combines the grinding action of a rotating abrasive tool and thermal melting action of electrochemical discharges to perform drilling of borosilicate glass. G-ECDD is performed using a normal electrochemical discharge machine set-up with a provision for using a rotating diamond-coated drill tool. The tool used is a hollow diamond core drill rather than the traditional solid abrasive tool. A spring-fed tool system was designed and developed to provide the tool-feed movement which will also help to maintain a balance between grinding action of diamond grits and thermal melting action of discharges. Preliminary experiments are conducted to identify the optimum spring force of the spring-fed system and tool rotational speed which can facilitate a balanced ECDM and grinding action for material removal. The effect of machining parameters like voltage, duty ratio, pulse cycle time and electrolyte concentration on material removal rate (MRR) and hole radial overcut (ROC) is investigated using response surface methodology (RSM). Duty ratio and voltage are found to be the most significant factors contributing MRR. Voltage and pulse cycle time are identified as the main factors controlling radial overcut of the drilled holes. Second-order regression models for MRR and ROC are developed using the data collected from the experiments using RSM. Grey relational analysis was used to optimize this multi-objective problem. A voltage of 90 V, duty ratio of 0.7, cycle time of 0.002 s and an electrolyte concentration of 3.5 M are found to be the best combination for optimizing the responses. Deterioration of bonding material and dislodging of diamond grits are found to be the major modes of tool wear during G-ECDD. The use of high-frequency pulsed DC increased the tool wear rate due to the less time available for heat dissipation between discharge cycles. Moreover, the wear at the end face of the tool will be accelerated due to the concentration of current density at edges during high-frequency operation. From the microscopic images of the machined surface, the material removal mechanisms involved in G-ECDD are found to be a combination of thermal melting by discharges, grinding action of diamond grits and high-temperature chemical etching effect of the electrolyte.
关键词： Electrochemical discharge machining,Response surface methodology,Tool wear,Radial overcut,Grey relational analysis,Material removal rate,Material removal mechanism,Grinding
更新于2025-09-11 14:15:04
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Experimental investigations on super-smooth polishing of strontium titanate based ceramics substrates
摘要： Strontium titanate (SrTiO3) is a new type of multi-function electronic ceramic material. SrTiO3 ceramic substrates with a high dielectric constant can be obtained by non-pressurised sintering using ultrathin blanks, which result in the characteristics of thin, soft, brittle and warped. So that SrTiO3 ceramics substrates need to be polished to improve surface quality and dimensional precision before application. In this research, polish experiments with various processing parameters on the surface roughness, the material removal rate and the surface morphologies of SrTiO3 ceramic substrates were conducted. The results show that the SrTiO3 ceramic substrate with a highest quality surface was obtained in the condition: employing a brown polyurethane pad to polish the substrates at a polishing velocity of 45 r/min. Meanwhile, the slurry flow rate, the concentration of the polishing slurry and the polishing pressure were 20 ml/min, 4 wt% and 15.043 kPa, respectively, which rates with an overall and a partial surface roughness of Ra 0.01 μm and Ra 4 nm, respectively. While some new micro-scratches were generated on the surface of the SrTiO3 ceramics substrate in the polishing process because the embedding and scratching of abrasive particle led to expose the inherent pores and grain boundaries.
关键词： ceramic substrate,material removal rate,strontium titanate,polishing,surface roughness
更新于2025-09-10 09:29:36
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Materials Science and Technology of Optical Fabrication || Material Removal Rate
摘要： This chapter covers the last of the four major characteristics of optical fabrication, material removal rate (see Figure 1.6). As discussed in Chapter 1, the macroscopic material removal rate is governed by the Preston equation (Equation (1.3)), where removal rate largely scales linearly with applied pressure and relative velocity, and all the process and material parameters are lumped into the Preston coefficient kp. The Preston equation can be applied to both grinding (which is discussed in Section 5.1) and polishing (Section 5.2). The parameters that govern material removal rate and resulting surface roughness are intimately connected. Hence, the principles of the ensemble Hertzian multi-gap (EHMG) and island distribution gap (IDG) models, as discussed in Chapter 4, can be largely applied when discussing polishing material removal rate.
关键词： optical fabrication,IDG model,material removal rate,Preston equation,grinding,polishing,EHMG model
更新于2025-09-10 09:29:36
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Materials Science and Technology of Optical Fabrication || Surface Figure
摘要： As described in Section 1.2, one of the major characteristics of the final optic is the surface figure, or long-range surface shape of the workpiece. Achieving the desired surface figure is a primary objective in fabricating an optic, because surface figure influences the wavefront modification of the incoming light, both in transmission and reflection. At the most basic level, the final surface figure of the workpiece is simply determined by its initial surface shape and the amount of material removed from each point on the workpiece surface, discounting residual stress changes. Hence, to quantitatively (i.e. deterministically) determine surface figure evolution in a given finishing process, one must understand all the phenomena that contribute to the material removal rate at each point and as a function of time. A useful approach to describe and organize these phenomena is to expand the traditional material removal rate Preston equation (Equation (1.3)). Preston’s equation may be described in a more general form as follows: [1]
关键词： material removal rate,Preston equation,surface figure,optical fabrication,polishing
更新于2025-09-09 09:28:46