Machinability Analysis During Laser Assisted Turning of Aluminium 3003 Alloy

Proceedings of the Institution of Mechanical Engineers, Part B:

2023

Self Cite

Surface integrity of the machined surface is an important aspect considering their surface alterations, metallurgical effects, and mechanical characteristics during the machining process. Industries have been seeking a capable machining technology that can improve the machining process capabilities especially in an eco-friendly manner. Hybrid machining processes have shown significant improvement in machining performance when compared with the conventional turning (CT) process without using any cutting fluids. Moreover, a recently developed hybrid machining technology, that is, ultrasonic-vibration-laser assisted turning (UVLAT) has shown better machinability than the CT process. Therefore, an attempt has been made to improve the surface integrity of aluminum 3003 alloy in terms of machining forces, surface roughness, surface damage, microstructure, microhardness, residual stresses, and corrosion behavior during the UVLAT process. A comparative surface integrity analysis has been performed among the CT, ultrasonic vibration assisted turning (UVAT), laser assisted turning (LAT), and UVLAT processes. Significant improvement in the surface integrity has been observed for the aluminum 3003 alloy during the UVLAT process in comparison to the CT, UVAT, and LAT processes. The periodic separation of the cutting tool and thermal softening of the workpiece material, simultaneously during the UVLAT process is the possible reason for the improvement in surface integrity. Results demonstrated that the UVLAT process has an excellent potential to enhance the surface integrity of aluminum alloys and is better than the CT, UVAT, and LAT processes.

show abstract

Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Surface integrity analysis of aluminum 3003 alloy during ultrasonic-vibration-laser assisted turning

Proceedings of the Institution of Mechanical Engineers, Part B:

2023

Self Cite

show abstract

“…Higher machining temperature and sticking of the aluminium particles led to the generation of higher damage on the workpiece surface and higher surface roughness. Deswal and Kant reported higher surface roughness during the machining of aluminium alloy for the LAT process than the CT process [17]. They revealed that the adhesion of aluminium alloy on the tool rake face and built-up edge could have occurred because aluminium alloys possess a higher chemical affinity towards the carbide cutting tool materials to form an adhesive layer.…”

Section: Surface Roughnessmentioning

confidence: 99%

“…Due to the sticking of the particles, these could have ploughed on the machined surface which led to the generation of some scratches and particle adhesion. Scratches and particle adhesion were observed on the machined surface during the LAT process in the work of Deswal and Kant [17]. They explained that the material adhered on the cutting tool could have ploughed on the machined surface due to the ductile nature of the aluminium alloy, resulting in scratches and particle adhesion on the machined surface during the LAT process.…”

Section: Surface Damagementioning

confidence: 99%

“…For brittle materials, the yield strength of the material is reduced below the fracture resistance and the behavior of the brittle material changes into brittle-to-ductile at high temperatures, making machining relatively easier [15]. The yield strength of the material is decreased whereas ductility is increased at high temperatures for the ductile material which results in the reduction of tool wear and cutting force, and improvement in the surface quality of the machined surface [16]. Besides, the laser heat source has been found to be beneficial compared to the other thermal sources during the turning process because of the various unique properties such as localized, rapid, and controlled heating at the workpiece surface [17].…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Radial direction ultrasonic-vibration and laser assisted turning of Al3003 alloy

2023

Mater. Res. Express

Self Cite

The utilization of various energy sources to assist the machining process has become prominent to achieve substantial improvement in machining performance. These energy sources have also resulted in an alternative to cutting fluids which is safer for both the universe and human beings. The combined action of laser and ultrasonic vibration energies during the turning process has shown significant achievement in machining process capabilities. Therefore, an attempt has been made to provide ultrasonic vibration in the radial direction and laser to preheat aluminium 3003 alloy simultaneously during the ultrasonic-vibration-laser assisted turning (UVLAT) process. Machining performance has been analyzed in terms of machining forces, machining temperature, chip morphology, surface damage, and surface roughness. A comparative machining performance analysis has been carried out among the conventional turning (CT), laser assisted turning (LAT), ultrasonic vibration assisted turning (UVAT), and UVLAT processes. The outcomes of the current study indicate significant benefits of the UVLAT process on the machining performance of aluminium 3003 alloy. However, surface damage and surface roughness have been affected negatively during the UVLAT process due to the pin-point hammering and particle adhesion on the workpiece part. Hence, the selection of vibration direction is a critical factor during the vibration machining processes.

show abstract

Synergistic effect of ultrasonic vibration and laser energy during hybrid turning operation in magnesium alloy

Int J Adv Manuf Technol

2022