Experimental characterization and finite element modeling of the residual stresses in laser-assisted mechanical micromachining of Inconel 625

Abstract

Laser-assisted mechanical micromachining offers the ability to machine difficult-to-cut materials, like superalloys and ceramics, more efficiently and economically by laser-induced localized thermal softening prior to cutting. Laser-assisted mechanical micromachining is a micromachining process with localized laser heating which could affect the cutting forces and the machined surface integrity. The residual stresses obtained in the laser-assisted mechanical micromachining process depend on both mechanical loading and the laser heating. This article focuses on the experimental process characterization and prediction of the cutting forces and the residual stresses in a laser-assisted mechanical micromachining–based orthogonal machining of Inconel 625. The results show that the laser assistance reduces the mean cutting forces by ∼25% and enhances the normal compressive residual stress at the surface by ∼50%. Since microscale residual stress measurement is very time-intensive, a coupled-field thermo-mechanical finite element model of laser-assisted mechanical micromachining has been developed to predict the temperature, cutting forces and the residual stresses. The cutting forces and residual stresses’ predictions are in good agreement with the measured values during machining. In addition, parametric simulations have been carried out for laser power, cutting speed, cutting edge radius, rake angle, laser location and laser beam diameter to study their effect on cutting forces and surface residual stresses.

Study on the Performance of laser-assisted fast tool servo machining device for glass-ceramic

“…25 Samanta et al carried out laser-assisted mechanical micromachining experiments on Inconel 625, which proved that the method can reduce cutting force by 25%. 22,26 LAM is not only suitable for traditional turning but also gradually applied to diamond ultra-precision turning. Hossein Shahinian et al established an experimental system for micro laser-assisted diamond cutting of single-crystal Si.…”

Developing Laser-Assisted Machining Process for Nickel Based Superalloy IN625 Using Experimental and Statistical Analysis

“…To overcome the issues associated with conventional machining of hard-to-cut materials, advanced and hybrid machining processes have been researched. These include Cryogenic cooling [3], Minimum quantity lubrication (MQL) [4], Vibration-assisted machining (VAM) [5], modi cation of cutting tool surface with different micro-textures using femtosecond laser [6], and various Thermal-assisted machining (TAM) processes like Plasma-assisted machining (PAM) [7], Induction-assisted machining (IAM) [8], and Laser-assisted machining (LAM) [9][10][11][12][13][14][15][16][17][18][19][20]. In recent years, LAM has become the preferred alternative due to the favorable properties of laser beams, such as good focusing ability, localized heating, and ease of automation.…”

The study on surface integrity on laser-assisted turning of SiCp/2024Al

“…The experimental results show that LAM can reduce the wear of cutting tools, improve tool life, the service life of the cutting tool up to more than 180%. Avik Samanta et al [18] studied the experimental process characterization and prediction of the cutting force and residual stress of LAM Inconel 625. The results show that the average cutting force is reduced by 25% and residual compressive stress is increased by 50%.…”