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Effect of laser texturing on the performance of ultra-hard single-point cutting tools
摘要： This paper investigates the cutting performance and anti-adhesive properties of textured single-point polycrystalline diamond (PCD) cutting tools in machining Aluminium 6082 alloys. The micro/nano textures were first milled using a fibre laser (1064-nm wavelength) at different power intensities, feed speeds and pulse durations, and finally characterised using scanning electron microscopy, white light interferometry and energy dispersive X-ray spectroscopy. The effect of different textures on the cutting performance was investigated in turning tests under dry cutting conditions. The test was stopped at regular lengths of cut to allow analysis of height of adhesion through 3D white light interferometry. The data processing of the cutting forces and the microscopical characterisation of the tested cutting tools enabled the evaluation of the effects of texture design, friction coefficient and adhesive properties. The results indicated that feed force in tools with grooves perpendicular to the chip flow direction (CFD) was more stable (20–40 N) than the benchmark (6–41 N). Similarly, the thrust force for tools with grooves parallel to CFD and grooves perpendicular to CFD showed a homogeneous trend fluctuating between 60 and 75 N as compared with the benchmark (ranging between 73 and 90 N). For texture depth in the order of 260 nm and post process roughness in the order of tens of nanometers, a reduction of average friction coefficient (0.28 ± 0.14) was reported when using lasered inserts with grooves parallel to the chip flow direction compared with the benchmark tools (0.34 ± 0.26) corroborated by reduced stiction of workpiece material on the rake face. In machining via textured tools with grooves perpendicular to CFD, the cutting forces were reduced by 23%, and the surface quality of the machined workpiece was improved by 11.8%, making this geometry the preferred choice for finishing applications. Using grooves parallel to CFD reduced the cutting forces by 11.76%, adhesion by 59.36% and friction coefficient by 14.28%; however, it increased the surface roughness of the machined workpiece, making this geometry suitable for roughing operations. For the first time, laser manufacturing is proposed as a flexible technique to functionalise the geometrical and wear properties of PCD cutting tools to the specific applications (i.e. roughing, finishing) as opposed to the standard industrial approach to use microstructurally different PCDs (i.e. grain size and binder %) based on the type of operation.
关键词： Adhesion,Dry cutting,Nanosecond pulse,Laser milling,Polycrystalline diamond insert,Laser surface texturing,Cutting forces
更新于2025-09-16 10:30:52
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Effect of Laser Process Parameters on Laser Assisted Machining Of Inconel 718: Statistical – Regression Analyses
摘要： This paper discusses the effect of laser-assisted process parameters on cutting forces and surface temperature during laser assisted machining (LAM) of Inconel 718. The heat source used for pre-heating the surface is Nd:YAG laser source. Cutting speed, feed rate and laser power are the process parameter assessor for cutting force and cutting temperature. The experiments are planned and results are collected based on Taguchi’s L27 orthogonal design. The factor effect on output responses are analysed using a main effect plots (2D) and its significance is perceived from analysis of variance (ANOVA). Results reveal that cutting speed bags a maximum contribution of 56%, followed by cutting speed * feed rate as 24%, feed rate * laser power as 10.5 % and feed rate as 10%. Finally, the benefit of LAM was shown by 55% decrease in feed force (Fx), 50% decrease in thrust force (Fy) and 60% decrease in cutting force (Fz), as compared to those of the conventional machining. Additionally, it is also recommended to employ a work surface temperature in the range of 750?C–887?C during LAM of this Inconel 718 alloy to have maximum process benefits. The developed regression model reveals the goodness of fit with experimental data has high determination coefficient i.e. R2 = 0.91 for tangential force and 0.71 for surface temperature.
关键词： regression analysis,Statistical analysi,cutting forces,surface temperature
更新于2025-09-16 10:30:52
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Estimation of Optimal Laser Parameters On Inconel 718 By Taguchi Methodology
摘要： Inconel 718 is a representative of high temperature alloy which poses substantial difficulties in machining processes. High strength, high cutting temperature and a subsequent work hardening during machining process adversely affect the cutting force, surface integrity, tool life and chip breakability. The above difficulties have been disproving by employing the Laser Assisted Machining (LAM). LAM is a hybrid technique and used to machining the work-piece with conventional tool after softening it with laser emitted heat. An attempt has been made in the present study for an experimental investigation on the machining attributes of 718 Inconel super alloy during laser assisted machining using uncoated carbide insert. Experimental plan is designed based on Taguchi’s L18 mixed orthogonal array of design of experiment. Three response values such as cutting force, surface roughness and tool wear are measured and their effects are studied. The variability due to the machining parameters are dispensed using variance test. Predictive regression equations are developed for the estimation of all the quality characteristics. Also the Pearson correlation coefficient analysis is calculated to analyze the correlation between the input parameters and quality characteristics. Results showed a strong correlation between the feed rate and the cutting force and surface roughness followed by cutting speed. The results obtained from experiments are analyzed to predict the optimal machining conditions using desirability approach. At the optimal laser parameters, the tool life, when laser beam is used, is improved by 9% compared to conventional machining.
关键词： cutting forces,Taguchi method,surface roughness,tool wear,laser parameters
更新于2025-09-16 10:30:52