The promising processing techniques of micro scale parts are very important in products miniaturization and functions enhancement. Combination of two or more processing techniques gives better processing performance especially when dealing with difficult-to-cut materials. For that reason, the combination of laser beam and micro milling process has been widely studied and proven efficient in reducing cutting force and tool life extension. However, this process needs a precise temperature control in order to eliminate heat effect generated by laser beam irradiation. In this study, temperature distributions are determined numerically to characterize the melted zone and heat affected zone geometry. From the results, the estimation of tool and micro milling cutter distance together with the allowable depth of cut are determined.
Nickel-based alloy can be found in different industrial applications especially in aircraft engines and hot end components of various types of gas turbines with its high strength, strong corrosion resistance and excellent thermal fatigue properties and thermal stability compared to conventional materials. However, nickel-based alloy is one of the extremely difficult-to-cut materials. During the machining process, the interaction between the tool and the workpiece causes severe plastic deformation and intense friction at the tool-workpiece interface. Because of the increasing demands in industries, any improvement of conventional machining processes or any other deployment of additional technique is directly related to higher productivity.Thermal-assisted machining (TAM) has become an effective alternative to the conventional machining of these difficult-to-cut materials. Various types of heating methods and the beneficial effects on machining of nickel-based alloys are discussed in this chapter. Finally, TAM was proven as an efficient technique to increase the machinability of nickel-based alloys in terms of tool life, surface roughness and cutting force.
Micro milling of super alloy materials such as nickel based alloys such as Inconel 718 is challenging due to the excellent of its mechanical properties. Therefore, new techniques have been suggested to enhance the machinability of nickel based alloys by pre-heating the workpiece’s surface to reduce its strength and ductility. The prediction of fluctuated temperature distribution generated by pulsed wave laser in laser assisted micro milling (LAMM) is crucial. The selection of processing parameter by minimize the effect on the processing characteristic is decisive to ensure the machining quality is high. Determining the effect of heat generated in underneath surface is important to make sure that the cutting tools are able to cut the material with maximum depth of cut and minimum defects in terms of tool wear and tool life. In this study the simulation was carried by using Ansys APDL. In order to confirm the actual and distribution irradiation of temperature from simulation, an experimental was done to validate the results. The experiment was conducted by using Nd:YAG laser with wavelength 1064 nm.
Abstract. Dynamic analysis is very important in developing machine structure to sustain the required accuracy, reliability and productivity. The objective of this study is to conduct a dynamic and modal analyses of micro-milling machine. The machine designs were predicted by comparing the Finite Element Analysis (FEA) using ANSYS software and experimental hammer testing. Two micro-milling machine designs have been proposed. Natural frequency and mode shape was analyzed in modal analysis which show the result that first mode recorded frequency of 92.086 Hz for design A and 154.78 Hz for design B. Natural frequency of design B was higher than design A. From the comparision, it can be concluded that Design B was selected as a best design.
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