Process parameters influence on laser-assisted machining-induced residual stresses

Khajehzadeh, Mohsen; Razfar, Mohammad Reza

doi:10.1080/10426914.2020.1784930

Cited by 18 publications

(7 citation statements)

References 22 publications

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“…Apart from that, a slower cooling rate was observed in the LAT process which acts as a stress relieving heat treatment process, resulting in a reduction in tensile residual stresses. 39 Higher compressive residual stresses were achieved in the UVLAT process than in the CT, UVAT, and LAT processes. The simultaneous application of laser and ultrasonic vibration energies was able to generate lesser machining forces and higher microhardness due to the separation characteristics and thermal softening phenomenon which eventually led to higher compressive residual stresses when compared with other processes.…”

Section: Resultsmentioning

confidence: 90%

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

Deswal

Kant

2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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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.

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Section: Resultsmentioning

confidence: 90%

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

Deswal

Kant

2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…According to the results of ANOVA that are provided in Supplementary Table 5 (a), the parameters affecting T t include the cutting speed, feed, nano-particles concentration and interaction effect of parameters as well as the second order effect of feed. Equation (5) shows the modified regression equation governing on T t ( C):…”

Section: Workpiece and Cutting Tool Temperaturesmentioning

confidence: 99%

“…4 Another technique to reduce thermo-mechanical loading, thereby machining residual stresses is to develop machining techniques such as heat assisted machining; in this technique, an exterior local heat source such as laser, will be applied to the material which is about to be cut, in order to significantly reduce workpiece yield strength and work hardening; thereby, reducing the machining induced residual stresses. 5 Using advanced cutting tools such as Cubic Boron Nitride (CBN), Poly Crystalline Cubic Boron Nitride (PCBN) and ceramics is another way to reduce machining thermo-mechanical loading. For instance, recently a new coating technique called High Power Impulse Magnetron Sputtering (HiPIMS) has been developed to deposit Nano-Composite and Nano-Crystalline coatings on carbide cutting tools; these coated inserts have been reported to have an effective role in reducing machining forces and cutting temperatures, thereby, reducing the machining induced residual stresses.…”

Section: Introductionmentioning

confidence: 99%

Nano-lubricant influence on surface residual stresses in hard milling

Raftar

Kaveh

Khajehzadeh

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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Residual stress could be induced by machining processes like milling which can greatly affect the fatigue life of fabricated parts, especially in dynamic loading conditions. In metal cutting operations, machining induced residual stresses can be explained in the terms of machining forces and temperatures of the cutting zones. This thermo mechanical loading along with the resulted metallurgical changes are the main sources of residual stresses generation at the surface of machined workpiece. Researchers have proved the superior properties of nanofluids over the conventional coolants to reduce the intensity of thermo mechanical loading in machining process which will affect the residual stresses caused by machining. Therefore, in this paper, silver nanoparticles in the water-soluble oil have been used for reducing the mechanical and thermal loads in the milling process. The cutting forces, temperature of the cutting zone, surface roughness and the residual stress of machined surface have been measured experimentally in milling of hardened steel AISI 4140 for various nanoparticle’s concentration, feeds and cutting speeds. Results show that increasing the concentration of Nano-particles in base fluid from 0.5 to 3.0% wt., will make machining surface residual stresses more compressive averagely by about 66.67% compared to conventional cutting fluid.

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“…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.…”

Section: Introductionmentioning

confidence: 99%

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

Rao,

Tak,

Rao

et al. 2023

Lasers Manuf. Mater. Process.

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This study evaluated the optimization of process parameters in laser-assisted turning of IN625 nickelbased superalloy. IN625 is renowned for its high-temperature strength and work-hardening properties, making it challenging to machine using traditional techniques. In order to overcome this di culty, a laserassisted machining setup was employed that combined a conventional lathe with a 6 kW bre-coupled diode laser and dynamometer. The Box-Behnken design of experiments strategy based on Response Surface Methodology was used to optimize the machining conditions. The interplay between various machining properties, such as cutting forces, ank wear, and surface roughness, and machining process parameters, such as laser power, spindle speed, feed rate, and depth of cut, was investigated. The optimal parameters for laser-assisted turning of IN625 alloy included a laser power of 625 W, speed of 45 m/min, and feed of 0.15 mm/rev. These parameters led to reductions in cutting forces of 20% (F x ), 17% (F y ), 30% (F z ), as well as maximum ank wear and surface roughness of 18% and 16%, respectively. This study provides an effective strategy for optimizing the machining of IN625 alloys, which is di cult to machine by traditional techniques due to its high-temperature strength and work-hardening properties.

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Process parameters influence on laser-assisted machining-induced residual stresses

Cited by 18 publications

References 22 publications

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

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

Nano-lubricant influence on surface residual stresses in hard milling

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

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