Experimental analysis and evaluation of the cutting performance of tools in laser-assisted machining of fused silica

Song, Huawei; Li, Jialun; Dan, Jinqi; Ren, Guang‐Jie; Xiao, Junfeng

doi:10.1016/j.precisioneng.2018.11.014

Cited by 21 publications

(4 citation statements)

References 22 publications

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“…Thermal-assisted machining (TAM) was proposed in the 1950s [41]. Its advantage is that preheating can not only reduce the ultimate strength of materials but also promote plastic deformation of hard materials during processing.…”

Section: Introductionmentioning

confidence: 99%

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

et al. 2023

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Energy field-assisted machining technology has the potential to overcome the limitations of machining difficult-to-machine metal materials, such as poor machinability, low cutting efficiency, and high energy consumption. High-speed dry milling has emerged as a typical green processing technology due to its high processing efficiency and avoidance of cutting fluids. However, the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult to meet the continuous milling requirements for difficult-to-machine metal materials. The introduction of advanced energy-field-assisted green processing technology can improve the machinability of such metallic materials and achieve efficient precision manufacturing, making it a focus of academic and industrial research. In this review, the characteristics and limitations of high-speed dry milling of difficult-to-machine metal materials, including titanium alloys, nickel-based alloys, and high-strength steel, are systematically explored. The laser energy field, ultrasonic energy field, and cryogenic minimum quantity lubrication energy fields are introduced. By analyzing the effects of changing the energy field and cutting parameters on tool wear, chip morphology, cutting force, temperature, and surface quality of the workpiece during milling, the superiority of energy-field-assisted milling of difficult-to-machine metal materials is demonstrated. Finally, the shortcomings and technical challenges of energy-field-assisted milling are summarized in detail, providing feasible ideas for realizing multi-energy field collaborative green machining of difficult-to-machine metal materials in the future.

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Section: Introductionmentioning

confidence: 99%

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

et al. 2023

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“…Abrasive or tool wear is almost inevitable in ultra-precision machining of hard and brittle materials [8,9]. Song et al [10] carried out laser assisted machining (LAM) experiments of fused silica with polycrystalline diamond tool (PCD), polycrystalline cubic boron nitride tool (PCBN), and tinned Al 2 O 3 /TiC ceramic tool, respectively, clarified the wear mechanism of the three tools, and pointed out that severe wear will affect the life of the tool. Chen et al [11] found that the passivation of the grinding wheel will increase the friction between the grinding wheel and the workpiece, and the cutting force state and passivation degree of the grinding wheel can be reflected through the noise spectrum during processing.…”

Section: Introductionmentioning

confidence: 99%

An Analysis of the Effect of Abrasive/Tool Wear on the Ductile Machining of Fused Silica from the Perspective of Stress

Guo

Yuan

et al. 2022

Micromachines

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Understanding the influence mechanism of abrasive/tool wear on machining is the key to realize high-efficiency ultra-precision machining of fused silica. To explore the effect of abrasive/tool wear on ductile machining, the smoothed particle hydrodynamics (SPH) cutting models with different edge radii are established. Through the analysis of equivalent rake angle, hydrostatic pressure, cutting force and maximum principal stress with the Flamant’s formula, the influence of edge radii on ductile-brittle transition (DBT) is discussed for the first time. The simulation results show that when the edge radius increases from less to larger than the cutting depth, the equivalent rake angle changes from positive to negative, and the maximum hydrostatic pressure gradually increases, which is beneficial to promote the ductile processing. Meanwhile, with the rise of edge radius (i.e., abrasive/tool wear), both the cutting force and crack initiation angle increase, while the friction coefficient and normalized maximum principal decrease. When the value of normalized maximum principal stress exceeds 2.702, the crack in the workpiece begins to initiate, and its initiation angle calculated by the Flamant’s formula is in good agreement with the simulation results as well as less than 50°. Finally, the nano-scratch experiment was carried out, and the material removal mechanism and friction coefficient f similar to the simulation were obtained, which further proved the accuracy of SPH model. This study is meaningful for understanding the effect of abrasive/tool wear on the removal mechanism of brittle materials and improving the quality and efficiency of cutting and grinding.

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“…Extensive research has been conducted on various ceramics and has proved in the past few decades that LAM is effective for machining brittle and hard materials [4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19][20]. In the early 1990s, scholars began to study the LAM of engineering ceramics [21].…”

Section: Introductionmentioning

confidence: 99%

Process Parameters Optimization Using Taguchi-Based Grey Relational Analysis in Laser-Assisted Machining of Si3N4

Zhao

Meng

et al. 2021

Materials

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Despite extensive research over the past three decades proving that laser-assisted machining (LAM) is effective for machining ceramic materials, which are affected by many machining parameters, there has been no systematic study of the effects of process parameters on surface quality in LAM ceramic materials. In this paper, the effects and optimization of laser power, spindle speed, feed rate, and cutting depth on surface roughness and work hardening of LAM Si3N4 were systematically studied, using grey relational analysis coupled with the Taguchi method. The results show that the combination of machining parameters determines the material removal mode at the material removal location, and then affects the surface quality. In ductile material removal mode, both the value of surface roughness and work hardening degree are smaller. Decreased surface roughness and work hardening degree can be obtained with smaller cutting depth and higher laser power.

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Experimental analysis and evaluation of the cutting performance of tools in laser-assisted machining of fused silica

Cited by 21 publications

References 22 publications

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

An Analysis of the Effect of Abrasive/Tool Wear on the Ductile Machining of Fused Silica from the Perspective of Stress

Process Parameters Optimization Using Taguchi-Based Grey Relational Analysis in Laser-Assisted Machining of Si3N4

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