Force modeling of Inconel 718 laser-assisted end milling under recrystallization effects

Pan, Zhipeng; Feng, Yixuan; Lu, Yu-Ting; Lin, Yu-Fu; Hung, Tsung-Pin; Hsu, Fu-Chuan; Liang, Steven Y.

doi:10.1007/s00170-017-0379-x

Cited by 44 publications

(13 citation statements)

References 20 publications

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“…In feed direction, the predicted value is 2.01 N which is 4.15% higher. In cutting direction, the prediction is 2.14 N and the error is 25.88% which is acceptable comparing with previous established conventional milling force predictive model [13]. When the ultrasonic vibration is applied, the average values decrease by 50% in feed direction and 35% in cutting direction.…”

Section: Validation By Experimental Datasupporting

confidence: 55%

“…At each specific tool angular position, the milling is considered as equivalent orthogonal cutting, and all cutting as well as tool geometry parameters are recalculated. The chip flow angle c  is calculated based on tool geometry and cutting parameters [13].…”

Section: Instantaneous Equivalent Cutting and Geometry Parameters Witmentioning

confidence: 99%

“…In current study, an analytical force predictive model is proposed which is able to characterize vibration in three directions and decide three types of tool-workpiece separation criteria. The previously proposed model [12][13][14][15][16][17][18] predicts the milling forces based on instantaneous tool rotation angle, feed rate, cutting speed, and axial depth of milling. At each specific tool angular position, the milling is considered as equivalent orthogonal cutting, and all cutting as well as tool geometry parameters are recalculated.…”

Section: Introductionmentioning

confidence: 99%

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Force Prediction in Ultrasonic Vibration-Assisted Milling

Feng

Hsu

et al. 2019

Preprint

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Force reduction is one of the most important benefit of applying ultrasonic vibration on milling. However, most of studies so far are limited to experimental investigation. In the current study, an analytical predictive model on cutting forces in ultrasonic vibration-assisted milling is proposed. The three types of tool-workpiece criteria are considered based on the instantaneous position and velocity of tool center. Type I criterion indicates that there is no contact if the instantaneous velocity is opposite to tool rotation direction. Type II criterion checks whether the vibration displacement is larger than the instantaneous uncut chip thickness. Type III criterion considers the overlaps between current and previous tool paths due to vibration. If none of these criteria is satisfied, milling forces are nonzero. Then the calculation is performed by transforming milling and tool geometry configuration to orthogonal cutting at each instant. The orthogonal cutting forces are predicted through the exhaustive search of shear angle and calculation of shear flow stress on tool-chip interface. The axial force is then calculated based on tool geometry, and the milling forces in feed, cutting, and axial directions are calculated after coordinate transformation. The proposed predictive force model in ultrasonic vibration-assisted milling is validated through comparison to experimental measurements on Aluminum alloy 2A12. The predicted values are able to match the measured milling forces with high accuracy of average difference of 13.6% in feed direction and 13.8% in cutting direction.

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Section: Validation By Experimental Datasupporting

confidence: 55%

Section: Instantaneous Equivalent Cutting and Geometry Parameters Witmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Force Prediction in Ultrasonic Vibration-Assisted Milling

Feng

Hsu

et al. 2019

Preprint

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“…In recent years, the material base for LAM has expanded to a wide range including ceramics [93,[104][105][106][107][108][109], high hardness steel [110,111], stainless steel [112], titanium alloys [113,114], nickelbased alloys [115], metal matrix composites [116][117][118][119], glass [120], semiconductors [121], and ceramic matrix composites [122]. The need for components with diverse geometric shapes has pushed the application of LAM from the dominant turning operation to milling [114,[123][124][125] and micromilling [126][127][128][129], drilling [130], orthogonal cutting [131], and grinding [132,133]. Over the years, the LAM field has attracted various research groups in the world and their engagement has advanced the field in various fronts as evidenced by the large number of studies reported every year.…”

Section: Prediction Of Mechanicalmentioning

confidence: 99%

Overview of Laser Applications in Manufacturing and Materials Processing in Recent Years

Shin

Lei

et al. 2020

Journal of Manufacturing Science and Engineering

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Recent years have witnessed a rapid growth of the laser market. Figure 1 shows the recent revenues of laser sales with about 50% increase in revenue over recent four years , which far exceeds the growth of other industrial sectors. More than one third of this revenue belongs to the category of laser materials processing arena. Undoubtedly, lasers have been playing increasingly important roles in various industrial manufacturing sectors. This article is to capture some of important developments in the rapidly growing areas of laser-based manufacturing and materials processing and also describe important technological issues pertaining to various laser-based manufacturing processes. The topics to be covered in this paper include more popularly used processes in industry such as laser additive manufacturing, laser-assisted machining, laser micromachining, laser forming, laser surface texturing, laser welding, and laser shock peening, although there are several additional areas of laser applications. In each section, a brief overview of the process is provided, followed by critical issues in implementing the process, such as properties, predictive modeling, and process monitoring, and finally some remarks on future issues that can guide researchers and practitioners.

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“…To reduce the forces as well as tool wear, researchers have introduced several thermally enhanced machining technologies such as laser-assisted milling. The intense beam produced by laser increases the temperature in the region in front of cutting tool and therefore drops the flow stress and strain-hardening rate, leading to lower cutting forces [3,4]. Shi et al [5] evaluated the machinability of Inconel 718 after laser-assisted machining and concluded that cutting forces decreased by 18% in their experiments.…”

Section: Introductionmentioning

confidence: 99%

Microstructure-sensitive flow stress modeling for force prediction in laser assisted milling of Inconel 718

Pan

Feng

et al. 2017

Manufacturing Rev.

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-Inconel 718 is a typical hard-to-machine material that requires thermally enhanced machining technology such as laser-assisted milling. Based upon finite element analysis, this study simulates the forces in the laser-assisted milling process of Inconel 718 considering the effects of grain growth due to c 0 and c 00 phases. The c 00 phase is unstable and becomes the d phase, which is likely to precipitate at a temperature over 750°C. The temperature around the center of spot in the experiments is 850°C, so the phase transformation and grain growth happen throughout the milling process. In the analysis, this study includes the microstructure evolution while accounting for the effects of dynamic recrystallization and grain growth through the Avrami model. The grain growth reduces the yield stress and flow stress, which improves the machinability. In finite element analysis (FEA), several boundary conditions of temperature varying with time are defined to simulate the movement of laser spot, and the constitutive model is described by Johnson-Cook equation. In experiments, this study collects three sets of cutting forces and finds that the predicted values are in close agreements with measurements especially in feed direction, in which the smallest error is around 5%. In another three simulations, this study also examines the effect of laser preheating on the cutting forces by comparison with a traditional milling process without laser assist. When the laser is off, the forces increase in all cases, which prove the softening effect of laser-assisted milling. In addition, when the axial depth of milling increases, the laser has a more significant influence, especially in axial direction, in which the force with laser is more than 18% smaller than the one without laser. Overall, this study validates the influence of laser-assisted milling on Inconel 718 by predicting the cutting forces in FEA.

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Force modeling of Inconel 718 laser-assisted end milling under recrystallization effects

Cited by 44 publications

References 20 publications

Force Prediction in Ultrasonic Vibration-Assisted Milling

Force Prediction in Ultrasonic Vibration-Assisted Milling

Overview of Laser Applications in Manufacturing and Materials Processing in Recent Years

Microstructure-sensitive flow stress modeling for force prediction in laser assisted milling of Inconel 718

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