A Study on the Influence of Laser Parameters on Laser-Assisted Machining of AISI H-13 Steel

2019 ◽  
Vol 827 ◽  
pp. 92-97 ◽  
Author(s):  
Evaggelos Kaselouris ◽  
A. Baroutsos ◽  
T. Papadoulis ◽  
Nektarios A. Papadogiannis ◽  
Michael Tatarakis ◽  
...  
Keyword(s):  
Laser Beam ◽  
Cutting Forces ◽  
Local Heating ◽  
Orthogonal Cutting ◽  
Material Model ◽  
Beam Diameter ◽  
Laser Parameters ◽  
Laser Assisted Machining ◽  
Von Mises ◽  
Cutting Processes

The machinability of a steel workpiece through conventional and Laser-Assisted Machining (LAM) is studied by the help of the Finite Element Method (FEM). In LAM, the laser beam is applied as a heat source to ensure sufficient local heating of the workpiece at a certain distance from the cutting tool and the machinability of materials is increased since the values of the cutting forces are decreased. A thermostructural FEM model is developed to simulate the conventional and the LAM orthogonal cutting of AISI H-13 steel. The Johnson-Cook material model that takes into account the effect of plastic strain, strain rate and temperature, along with a fracture model, is used in the simulations. For varying feed rate, parametric simulations are carried out, for different test cases of the laser beam diameter and the laser heat flux. Key engineering parameters, like cutting forces, temperature distributions, Von Mises stresses and plastic strains, are compared for both cutting processes. This comparison leads to important notifications on the influence of the cutting and laser parameters to LAM. The obtained results indicate that LAM may improve the machinability of AISI H-13 steel by reducing the cutting forces to a maximum percentage of ~15%.

Force Analysis, Mechanical Energy and Laser Heating Evaluation of Scratch Tests on Silicon Carbide (4H-SiC) in Micro-Laser Assisted Machining (µ-LAM) Process

2009 ◽  
Author(s):  
Amir R. Shayan ◽  
Huseyin Bogac Poyraz ◽  
Deepak Ravindra ◽  
Muralidhar Ghantasala ◽  
John A. Patten
Keyword(s):  
Laser Beam ◽  
Cutting Forces ◽  
Laser Heating ◽  
Cutting Tool ◽  
Work Piece ◽  
Force Analysis ◽  
Diamond Cutting ◽  
Laser Assisted Machining ◽  
Scratch Tests ◽  
Diamond Cutting Tool

The purpose of applying a laser beam in the micro-laser assisted machining (μ-LAM) process is to preferentially heat and thermally soften the surface layer of the work piece material (4H-SiC) at the interface with a diamond cutting tool. In the μ-LAM process the laser beam (1480 nm and 400 mW) is delivered to the work piece material through a transparent diamond cutting tool. Thus the cutting tool and the laser system are integrated and coupled; in contrast with other LAM processes where the cutting tool and laser are separate and distinct systems. Scratches were made on a 4H-SiC substrate using the μ-LAM process. The characteristics of the scratches, such as depth and width, are principally a function of the cutting tool geometry, applied forces, cutting speed, and laser heating. White light interferometer microscopy and Atomic Force Microscopy (AFM) techniques were used to measure the geometry (depth and width) of the scratches. Force analysis was carried out to evaluate the laser heating effect on the cutting forces and the measured depth of cut. The force analysis included an evaluation of the mechanical work, specific energy, and understanding the effect of laser heating on the cutting process. The scratch tests performed on 4H-SiC with the laser heating showed that there is a greater than 50% reduction in relative calculated hardness values of work piece material, resulting in a significant reduction in cutting forces.

3D Simulation of Laser Assisted Side Milling of Ti6Al4V Alloy Using Modified Johnson-Cook Material Model

2013 ◽  
Vol 554-557 ◽  
pp. 2054-2061 ◽  
Author(s):  
Hassan Zamani ◽  
Jan Patrick Hermani ◽  
Bernhard Sonderegger ◽  
Christof Sommitsch
Keyword(s):  
Tool Wear ◽  
Laser Beam ◽  
Cutting Forces ◽  
Three Dimensional ◽  
Material Model ◽  
Element Model ◽  
Milling Process ◽  
Machining Processes ◽  
Side Milling ◽  
Three Dimensional Finite Element

During machining of hard materials, one approach to reduce tool wear is using a laser beam to preheat the material in front of the cutting zone. In this study, a new concept of laser-assisted milling with spindle and tool integrated laser beam guiding has been tested. The laser beam is located at the cutting edge and moving synchronously with the cutter. In experiment, a reduction in the resulting process cutting forces and tool wear has been observed in comparison to milling without laser. A three-dimensional finite element model in DEFORM 3D was developed to predict the cutting forces in the milling process with and without an additional laser heat source, based on a Johnson-Cook-type material constitutive model adapted for high strains and strain rates. Both in experiment and simulation, the deformation behavior of a Ti-6Al-4V workpiece has been investigated. The comparison of the resulting cutting forces showed very good agreement. Thus the new model has great potential to further optimize laser assisted machining processes.

Parameters Evaluation of Bond-Coat Deposited by CO2 Laser Beam for Aeronautical Turbine Blades

2016 ◽  
Vol 869 ◽  
pp. 685-688
Author(s):  
Viviane Teleginski ◽  
Júlio César Gomes Santos ◽  
Daniele Cristina Chagas ◽  
Jéssica Fernanda Azevedo ◽  
Ana Claudia Costa Oliveira ◽  
...  
Keyword(s):  
Laser Beam ◽  
Bond Coat ◽  
Local Heating ◽  
Turbine Blades ◽  
High Hardness ◽  
Scanning Speed ◽  
Ceramic Coatings ◽  
Laser Parameters ◽  
High Cooling Rates ◽  
Steel Substrates

The high temperature environments where aeronautical turbine blades are exposed makes mandatory the use of ceramic coatings. A bond coat comprised by a MCrAlY alloy (M=Co, Ni) is necessary to match the blade metallic substrate with the ceramic, also acting as a corrosion barrier. The laser treatment of metals and alloys is based in the surface local heating, followed by high cooling rates. The laser parameters such as scanning speed and laser power, plays an important role on the morphological, mechanical and chemical characteristics of the deposited material. In the present investigation, the NiCrAlY deposition was performed in stainless steel substrates with a CO2 laser beam. Different laser parameters of scanning speed and number of scanning cycles were implemented. The samples were characterized by optical microscopy and measurements of Vickers hardness. The results show that it is possible to achieve coatings with high hardness, free of pores or any pronounced defects, metallurgically bonded to the substrate.

On Methodologies inside Two Different Commercial Codes to Simulate the Cutting Operation

2011 ◽  
Vol 223 ◽  
pp. 162-171
Author(s):  
Yan Cheng Zhang ◽  
Domenico Umbrello ◽  
Tarek Mabrouki ◽  
Stefania Rizzuti ◽  
Daniel Nelias ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Chip Formation ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Cutting Operation ◽  
Cutting Processes ◽  
Cutting Model

Nowadays, numerical simulation of cutting processes receives considerable interest among the scientific and industrial communities. For that, various numerical codes are used. Nevertheless, there is no uniform standard for the comparison of simulation model with these different software. So, it is often not easy to state if a given code is more pertinent than another. In this framework, the present work deals with various methodologies to simulate orthogonal cutting operation inside two commercial codes Abaqus and Deform. The aim of the present paper is to build a common benchmark model between the two pre-cited codes which can initiate other numerical cutting model comparisons. The study is focused on the typical aeronautical material - Ti-6Al-4V - Titanium alloy. In order to carry out a comparative study between the two codes, some similar conditions concerning geometrical models and cutting parameters were respected. A multi-physic comprehension related to chip formation, cutting forces and temperature evolutions, and surface integrity is presented. Moreover, the numerical results are compared with experimental ones.

scholarly journals Determination of Johnson–Cook Constitutive Parameters for Cutting Simulations

Metals ◽  
2019 ◽  
Vol 9 (4) ◽  
pp. 473 ◽  
Author(s):  
Storchak ◽  
Rupp ◽  
Möhring ◽  
Stehle
Keyword(s):  
Constitutive Equation ◽  
Standardized Test ◽  
Orthogonal Cutting ◽  
Material Model ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Compression Tests ◽  
Machining Processes ◽  
Cutting Processes ◽  
Constitutive Parameters

The Johnson–Cook constitutive equation is very widely used for simulating cutting processes. Different methods are applied for establishing parameters of the constitutive equation. Based on the methods analysed in this study, two algorithms were worked out to determine the constitutive parameters for the prevailing conditions during cutting processes. In the first algorithm, all constitutive parameters were established simultaneously with standardized test methods. In the second algorithm, the constitutive parameters were established separately in accordance with the cutting conditions prevailing in machining processes. The developed methodology was verified with AISI 1045 heat-treatable steel and Ti10V2Fe3Al (Ti-1023) titanium alloy. The two materials were examined in standardized tensile and compression tests with varying strain rates and temperatures. In addition, the kinetic characteristics of the orthogonal cutting process were established. Based on the results obtained by experiment and the algorithms developed, the constitutive parameters for the cutting conditions were calculated. The parameters were used to determine the material model for simulating the orthogonal cutting process. The algorithms developed were verified by comparing the simulated and experimentally determined kinetic cutting characteristics, which confirmed their good quality.

Thermoviscoplastic modelling of drilling: Twist drills

2008 ◽  
Vol 222 (3) ◽  
pp. 403-411 ◽  
Author(s):  
A Nayebi ◽  
H Vaghefpour
Keyword(s):  
Cutting Forces ◽  
Material Flow ◽  
Thrust Force ◽  
Orthogonal Cutting ◽  
Material Model ◽  
Thermomechanical Properties ◽  
Twist Drill ◽  
Viscoplastic Material ◽  
Al 7075 ◽  
Twist Drills

In this paper, a viscoplastic material model is proposed for drilling of metals. An analytical model is developed for predicting thrust force and torque in drilling with a twist drill. The thermomechanical properties are taken into consideration to describe the material flow in the primary shear zone and at the element—chip interface. The Johnson—Cook model is used. A temperature friction law is introduced. The approach is based on representing the cutting forces along the cutting lips as a series of oblique elements. Similarly, cutting in the chisel region is treated as orthogonal cutting with different speeds depending on the radial location. The section forces obtained by the model are combined to determine the overall thrust force and drilling torque. The results of the model are compared with the experimental results obtained by Bagci and Ozcelik in 2006 on Al 7075-T651.

Numerical Modelling of Orthogonal Cutting of Electron Beam Melted Ti6Al4V

2015 ◽  
Vol 651-653 ◽  
pp. 1255-1260 ◽  
Author(s):  
Alberto Bordin ◽  
Stano Imbrogno ◽  
Stefania Bruschi ◽  
Andrea Ghiotti ◽  
Domenico Umbrello
Keyword(s):  
Electron Beam ◽  
Titanium Alloys ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Chip Morphology ◽  
Experimental Investigations ◽  
Element Analysis ◽  
Surgical Implants ◽  
Cutting Processes ◽  
Machining Operations

Finite element analysis of cutting processes of difficult-to-cut alloys is attracting more and more interest among the scientific community thanks to the change of predicting difficult to measure parameters as cutting forces, specific cutting pressures, cutting temperatures and the chip morphology. Aiming at calibrating and validating an FE numerical model, the predicted variables have to be compared with experimental results. Nowadays, Additive Manufactured Titanium alloys are being increasingly employed in the production of surgical implants and aero engine parts, but their peculiar fine acicular microstructure have to be taken into account dealing with their thermo-mechanical behavior as during machining operations. Based on the lack of literature works concerning experimental investigations on the machinability of Additive Manufactured Titanium alloys, this paper is aimed at investigating the cutting forces and temperatures arising during orthogonal cutting of an Electron Beam Melted (EBM) Ti6Al4V alloy.

RESEARCH ON CUTTING FORCES AND CUTTING TEMPERATURE IN ORTHOGONAL CUTTING SOFTWOOD AND HARDWOOD PARALLEL TO GRAIN

2018 ◽  
Vol 50 (4) ◽  
pp. 458-464
Author(s):  
Xu Bao ◽  
Xiaolei Guo ◽  
Pingxiang Cao ◽  
Linlin Xie ◽  
Minsi Deng
Keyword(s):  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Temperature

Stresses in Ultrasonically Assisted Turning

2006 ◽  
Vol 5-6 ◽  
pp. 351-358 ◽  
Author(s):  
N. Ahmed ◽  
A.V. Mitrofanov ◽  
Vladimir I. Babitsky ◽  
Vadim V. Silberschmidt
Keyword(s):  
Ultrasonic Vibration ◽  
Vibration Frequency ◽  
Cutting Forces ◽  
Plastic Material ◽  
Process Zone ◽  
Three Dimensional ◽  
Rate Sensitivity ◽  
High Strength ◽  
Material Model ◽  
Shear Stresses

Ultrasonically assisted turning (UAT) is a novel material-processing technology, where high frequency vibration (frequency f ≈ 20kHz, amplitude a ≈15μm) is superimposed on the movement of the cutting tool. Advantages of UAT have been demonstrated for a broad spectrum of applications. Compared to conventional turning (CT), this technique allows significant improvements in processing intractable materials, such as high-strength aerospace alloys, composites and ceramics. Superimposed ultrasonic vibration yields a noticeable decrease in cutting forces, as well as a superior surface finish. A vibro-impact interaction between the tool and workpiece in UAT in the process of continuous chip formation leads to a dynamically changing stress distribution in the process zone as compared to the quasistatic one in CT. The paper presents a three-dimensional, fully thermomechanically coupled computational model of UAT incorporating a non-linear elasto-plastic material model with strain-rate sensitivity and contact interaction with friction at the chip–tool interface. 3D stress distributions in the cutting region are analysed for a representative cycle of ultrasonic vibration. The dependence of various process parameters, such as shear stresses and cutting forces on vibration frequency and amplitude is also studied.

Sign in / Sign up

Export Citation Format

Share Document