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Investigation on laser-induced oxidation assisted micro-milling of Inconel 718
摘要： Poor surface quality and rapid tool wear are the main problems in micro-cutting of Inconel 718. In this study, a novel hybrid machining method named laser-induced oxidation assisted micro-milling is proposed to solve the aforementioned problems. A loose oxide layer and a relatively flat sublayer are formed on the material after laser irradiation. Under optimized laser parameters with a scanning speed of 1 mm/s and an average laser power of 4.5 W, the thicknesses of the oxide layer and the sublayer are 24 and 18 mm, respectively. The influence of cutting parameters on milling force, surface roughness, surface quality, and top burr size is studied in detail. Cutting force and thrust force in the proposed hybrid machining process are lower than those in the conventional micro-milling. Results show that for the investigated range of parameters, the optimal feed per tooth and depth of cut in the hybrid process are 3 mm/z and 3 mm, respectively. When using the optimal parameters, the surface roughness of the machined slot bottom is 108.5 nm. The top burr size on the up-milling side and the down-milling side is 26.8 and 36.2 mm, respectively. In addition, the tool wear mechanism is coating delamination in hybrid process, whereas chipping, coating delamination, tool nose breakage, and adhesion are the main tool wear mechanism in the conventional micro-milling. For the same amount of material removal, the proposed hybrid process can decrease the tool wear and enhance the service life of the micro-end mill as compared to conventional micro-milling.
关键词： micro-milling,Inconel 718,surface quality,tool wear,laser-induced oxidation
更新于2025-09-19 17:13:59
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Study on laser-induced oxidation modification coupled with micro milling of WC-Co cemented carbide
摘要： Cemented carbide is known as “industrial tooth” and has wide applications in terms of military, aerospace and other fields. In this study, a compound processing approach named laser-induced oxidation modification coupled with micro milling (LCMM) is proposed to solve its poor micro machining performance. The oxidation mechanism of WC-Co cemented carbide is revealed. Surface morphology and cross-section of WC-Co cemented carbide are investigated after laser irradiation under various average laser power and two reaction environment. Research results present that at the average power of 5 W, scanning speed of 0.5 mm/s and oxygen-rich oxygen condition, the laser-induced oxidation process is optimal. The thickness of oxide layer and sub-layer is 9.1 μm and 2.7 μm, and the material surface generates porous and loose oxide layer. In addition, comparative analyses are performed and discussed in detail considering milling force, tool wear and surface quality of machined micro slot. In comparison with conventional micro milling (CONM), cutting force of Fx and thrust force of Fy generated in removing the oxide layer in LCMM are reduced by 56% and 58% to maximum extent, respectively. The machined surface quality in LCMM is better than that in CONM with a slower rate of increase in surface roughness (Sa). At ap = 2 μm and fz = 1.5 μm/z, surface quality of machined micro slot in LCMM is superior to that at other milling parameters, and the surface roughness reach 57 nm. Tool wear rate in LCMM is greatly improved and tool wear mechanism mainly includes slight adhesion wear and abrasion wear. While, in CONM the wear mechanisms are severe abrasion wear, chipping and adhesion wear. The tool service life in LCMM can be promoted more than double.
关键词： Micro milling,Surface quality,Cemented carbide,Laser-induced oxidation,Tool wear
更新于2025-09-16 10:30:52
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[IEEE 2019 IEEE International Conference on Manipulation, Manufacturing and Measurement on the Nanoscale (3M-NANO) - Zhenjiang, China (2019.8.4-2019.8.8)] 2019 IEEE International Conference on Manipulation, Manufacturing and Measurement on the Nanoscale (3M-NANO) - Study on Laser-assisted Machining of Aluminum-based Silicon Carbide
摘要： In order to explore the feasibility of laser-assisted machining (LAM) in the field of metal matrix composites (MMCs), an orthogonal precision micro-cutting experiment of 45% volume fraction aluminum-based silicon carbide (SiCp/Al) was carried out, and the experimental results were analyzed and discussed. The experimental results show that laser-assisted processing can improve the processing characteristics of SiCp/Al materials. Under the appropriate laser power, the laser assisted processing technology can effectively improve the surface roughness of the workpiece to be processed, obtaining a high-quality surface finish, and increase the tool wear resistance to a certain extent at the same time. Laser assisted machining technology can be applied to the processing of metal matrix composites.
关键词： surface morphology,laser-assisted,SiCp/Al,tool wear,surface roughness
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
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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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A novel algorithm for tool wear online inspection based on machine vision
摘要： To inspect the tool wear condition in the process of numerical control (NC) machining for difficult-to-cut material, an online inspection system for tool wear is developed based on machine vision. With the help of MATLAB software, a self-matching algorithm is proposed according to the characteristics of tool wear images. The corresponding user-friendly graphical user interface (GUI) of the algorithm is developed. The bottom edges are separated by the adaptive connecting domain labeling to analyze wear condition of each edge. Then, each edge is arranged regularly by the improved rotatory positioning. The cutting edge is extracted by the method of partial angle threshold to fit and calculate the bottom wear value. It is shown that the absolute values of errors on the maximum wear width are less than 0.007 mm by using the self-matching algorithm. In the case of severe wear and breakage, the absolute values of errors on the maximum wear width are less than 0.057 mm because of uneven reflected light. The system features high response speed, high inspecting accuracy, and anti-noise performance. It is proved to be able to increase the utilization of cutting tools and guarantee the quality of workpiece. This method is potential to guarantee the reliability of cutting tool in aerospace manufacturing.
关键词： Image processing,Tool wear,Machine vision,Self-matching algorithm,Online inspection
更新于2025-09-10 09:29:36