Laser micro-milling of bio-lox forte ceramic: An experimental analysis

Abdo, Basem M. A.; Anwar, Saqib; El-Tamimi, Abdualziz; Al‐Ahmari, Abdulrahman; Nasr, Emad Abouel

doi:10.1016/j.precisioneng.2018.04.001

Cited by 23 publications

(17 citation statements)

References 36 publications

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“…Before the final experiments were implemented, the selection of the laser and RUM key input parameters was essential. In this analysis, the process parameter ranges were specified based on previous studies of laser machining [45,47,[54][55][56][57] and RUM [58][59][60][61][62]. The preliminary experiments were also conducted to establish the exact levels of the process parameters which were later used for the final experiments.…”

Section: Machining Conditionsmentioning

confidence: 99%

“…It implies the bottom width produced in LBM is smaller than expected. This can be due to the inherent characteristics of the laser that it imparts some taper as the machining depth progresses [45]. Certainly, the LBM could not machine or transfer the necessary energy to maintain the channel's dimensional accuracy according to the expected one.…”

Section: Dimensional Accuracymentioning

confidence: 99%

“…Nonetheless, they both have their respective fundamental issues. LBM has problems with thermal damage, high surface roughness, and vulnerable dimensional precision [45][46][47]. RUM is also associated with high machining costs and low MRR [48].…”

Section: Introductionmentioning

confidence: 99%

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Micromachining of Biolox Forte Ceramic Utilizing Combined Laser/Ultrasonic Processes

et al. 2020

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Micromachining has gained considerable interest across a wide range of applications. It ensures the production of microfeatures such as microchannels, micropockets, etc. Typically, the manufacturing of microchannels in bioceramics is a demanding task. The ubiquitous technologies, laser beam machining (LBM) and rotary ultrasonic machining (RUM), have tremendous potential. However, again, these machining methods do have inherent problems. LBM has issues concerning thermal damage, high surface roughness, and vulnerable dimensional accuracy. Likewise, RUM is associated with high machining costs and low material-removal rates. To overcome their limits, a synthesis of LBM and RUM processes known as laser rotary ultrasonic machining (LRUM) has been conceived. The bioceramic known as biolox forte was utilized in this investigation. The approach encompasses the exploratory study of the effects of fundamental input process parameters of LBM and RUM on the surface quality, machining time, and dimensional accuracy of the manufactured microchannels. The performance of LRUM was analyzed and the mechanism of LRUM tool wear was also investigated. The results revealed that the surface roughness, depth error, and width error is decreased by 88%, 70%, and 80% respectively in the LRUM process. Moreover, the machining time of LRUM is reduced by 85%.

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Section: Machining Conditionsmentioning

confidence: 99%

Section: Dimensional Accuracymentioning

confidence: 99%

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Micromachining of Biolox Forte Ceramic Utilizing Combined Laser/Ultrasonic Processes

et al. 2020

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“…Results indicated that the best value of Ra = 3 µm was achieved under a certain range of the selected parameters. Many limitations such as high heat-affected zones, poor surfaces, a lack of geometrical accuracy, etc., that can be associated with laser ablation [5,[8][9][10]. Therefore, the machining of microchannel on advanced ceramics, like Al 2 O 3 , ZrO 2 , etc., is a difficult task as documented in earlier the studies.…”

Section: Introductionmentioning

confidence: 99%

Rotary Ultrasonic Machining of Alumina Ceramic: An Experimental Investigation of Tool Path and Tool Overlapping

2020

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Pocket milling has been regarded as one of the most widely used operations in machining. The surface quality of the machined pockets is an essential aspect of any engineering and medical applications. In the current study, rotary ultrasonic machining (RUM) was applied for milling micro-pockets on alumina (Al2O3) ceramic. The objective of this research was to analyze the effect of the tool overlapping parameters on the surface roughness, surface morphology and the profiles of the machined pockets. Subsequently, the effect of different tool path strategies was analyzed on the surface quality and the material removal rate (MRR) of the machined pockets. A scanning electron microscope is used for analyzing the tool wear mechanisms. The experimental results provide evidence that the surface roughness, surface morphology and the MRR have been significantly affected by the considered tool overlapping and the tool path strategies. Furthermore, among the selected tool overlapping parameters (5–25%) and the tool path strategies, the best surface roughness (Ra = 0.155 μm and Rt = 1.432 µm) of the machined pockets can be found at 20% of the tool overlapping with a mix of uni-directional and zigzag tool path strategy.

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“…However, LMM could induce thermal damage on the machined surface and produce a recast layer as well as heat-affected zone, thereby deteriorating surface quality and dimensional accuracy. 10…”

Section: Introductionmentioning

confidence: 99%

Investigation on laser-induced oxidation assisted micro-milling of Inconel 718

Xia

Zhao

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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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 μm, 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 μm/z and 3 μm, 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 μm, 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.

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Laser micro-milling of bio-lox forte ceramic: An experimental analysis

Cited by 23 publications

References 36 publications

Micromachining of Biolox Forte Ceramic Utilizing Combined Laser/Ultrasonic Processes

Micromachining of Biolox Forte Ceramic Utilizing Combined Laser/Ultrasonic Processes

Rotary Ultrasonic Machining of Alumina Ceramic: An Experimental Investigation of Tool Path and Tool Overlapping

Investigation on laser-induced oxidation assisted micro-milling of Inconel 718

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