Thermally enhanced machining of hard-to-machine materialsA review

International Journal of Machine Tools and Manufacture

Volumn 50, Issue 8, 2010, Pages 663-680

  Sun, S ^a,d,e   Brandt, M ^b,d,e   Dargusch, M S ^c,d,e  

^a SWINBURNE UNIVERSITY OF TECHNOLOGY   (Australia)

^b RMIT UNIVERSITY   (Australia)

^c UNIVERSITY OF QUEENSLAND   (Australia)

^d CAST Cooperative Research Centre   (Australia)

^e The University of Queensland   (Australia)

Author keywords

Cutting force; Heat source; Machinability; Material removal temperature; Thermally enhanced machining; Tool wear

Indexed keywords

MACHINABILITY; METALLIC MATRIX COMPOSITES; STRAIN HARDENING; WEAR OF MATERIALS;

CUTTING FORCES; ENGINEERING MATERIALS; HEAT SOURCES; LASER AND PLASMA; MATERIAL REMOVAL; MATERIAL REMOVAL MECHANISMS; TOOL WEAR; TOOL WEAR MECHANISM;

CUTTING TOOLS;

EID: 77955229690     PISSN: 08906955     EISSN: None     Source Type: Journal    
DOI: 10.1016/j.ijmachtools.2010.04.008     Document Type: Review

References (115)

1. W. Knig, A.K. Zaboklicki, Laser-assisted hot machining of ceramics and composite materials, in: International Conference on Machining of Advanced Materials, vol. 847, NIST Special Publication, Gaithersburg, MD, 1993, pp. 455463.
2. G. Chryssolouries, N. Anifantis, and S. Karagiannis Laser assisted machining: an overview Journal of Manufacturing Science and Engineering, Transactions of the ASME 119 1997 766 769
3. M. Weck, W.V. Zeppelin, C. Hermanns, Lasera tool for turning centres, in: M. Geiger, F. Vollertsen (Eds.), Laser Assisted Net Shape Engineering, Proceedings of the LANE'94, vol. 1, Meisenbach Bamberg, 1994, pp. 427437.
4. J.W. Novak, Y.C. Shin, and F.P. Incropera Assessment of plasma enhanced machining for improved machinability of Inconel 718 Journal of Manufacturing Science and Engineering, Transactions of the ASME 119 1997 125 129
5. C.E. Leshock, J.-N. Kim, and Y.C. Shin Plasma enhanced machining of Inconel 718: modeling of workpiece temperature with plasma heating and experimental results International Journal of Machine Tools and Manufacture 41 2001 877 897
6. L.N.L.D. Lacalle, J.A. Snchez, A. Lamikiz, and A. Celaya Plasma assisted milling heat-resistant superalloys Journal of Manufacturing Science and Engineering, Transactions of the ASME 126 2004 274 285
7. G. Madhavulu, and B. Ahmed Hot machining process for improved metal removal rates in turning operations Journal of Materials Processing Technology 44 1994 199 206
8. Y.C. Shin, and J.-N. Kim Plasma enhanced machining of Inconel 718, manufacturing science and engineering ASME MED 4 1996 243 249
9. T. Kitagawa, and K. Maekawa Plasma hot machining for new engineering materials Wear 139 1990 251 267
10. M. Anderson, R. Patwa, and Y.C. Shin Laser-assisted machining of Inconel 718 with an economic analysis International Journal of Machine Tools and Manufacture 46 2006 1879 1891
11. B.M. Jau, S.M. Copley, M. Bass, Laser assisted machining, in: Proceedings of the Ninth North American Manufacturing Research Conference, University Park, Pennsylvania, 1981, pp. 1215.
12. P. Dumitrescu, P. Koshy, J. Stenekes, and M.A. Elbestawi High-power diode laser assisted hard turning AISI D2 tool steel International Journal of Machine Tools and Manufacture 46 2006 2009 2016
13. S. Rajagopal, D.J. Plankenhorn, and V.L. Hill Machining aerospace alloys with the aid of a 15 kW laser Journal of Applied Metalworking 2 1982 170 184
14. L. zler, A. nan, and C. zel Theoretical and experimental determination of tool life in hot machining of austenitic manganese steel International Journal of Machine Tools and Manufacture 41 2001 163 172
15. K.P. Maitya, and P.K. Swain An experimental investigation of hot-machining to predict tool life Journal of Materials Processing Technology 198 2008 344 349
16. N. Tosun, and L. zler A study of tool life in hot machining using artificial neural networks and regression analysis method Journal of Materials Processing Technology 124 2002 99 104
17. M.A. Lajis, A.K.M.N. Amin, A.N.M. Karim, H.C.D.M. Radzi, and T.L. Ginta Hot machining of hardened steels with coated carbide inserts American Journal of Engineering and Applied Sciences 2 2009 421 427
18. A.K.M.N. Amin, S.B. Dolah, M.B. Mahmud, and M.A. Lajis Effects of workpiece preheating on surface roughness, chatter and tool performance during end milling of hardened steel D2 Journal of Materials Processing Technology 201 2008 466 470
19. A.K.M.N. Amin, and M. Abdelgadir The effect of preheating of work material on chatter during end milling of medium carbon steel performed on a vertical machining center (VMC) Journal of Manufacturing Science and Engineering, Transactions of the ASME 125 2003 674 680
20. T.L. Ginta, A.K.M.N. Amin, M.A. Lajis, A.N.M. Karim, and H.C.D.M. Radzi Improved tool life in end milling Ti-6Al-4V through workpiece preheating European Journal of Scientific Research 27 2009 384 391
21. A.K.M.N. Amin, and N.V. Talantov Influence of instability of chip formation and preheating of work on tool life in machining high temperature resistance steel and titanium alloy Mechanical Engineering Research Bulletin 9 1986 52 62
22. G. Barrow Machining of high strength materials at elevated temperature using electrical current heating CIRP Annals 14 1966 145 151
23. E.J. Krabacher, and M.E. Merchent Basic factor of hot machining of metals Journal of Engineering for Industry, Transactions of the ASME 73 1951 761 776
24. S. Lei, F. Pfefferkorn, A review of thermally assisted machining, in: Proceedings of the ASME International Conference on Manufacturing Science and Engineering, Atlanta, GA, October 15-7, 2007, pp. 112.
25. M. Anderson, and Y.C. Shin Laser-assisted machining of an austenitic stainless steel: P550 Proceedings of the Institution of Mechanical EngineersPart B: Journal of Engineering Manufacture 220 2006 2055 2067
26. H. Ding, and Y.C. Shin Laser-assisted machining of hardened steel parts with surface integrity analysis International Journal of Machine Tools and Manufacture 50 2010 106 114
27. J.C. Rozzi, F.E. Pfefferkorn, F.P. Incropera, and Y.C. Shin Transient thermal response of rotating cylindrical silicon nitride workpiece subjected to translating laser heat source, Part I: Comparison of surface temperature measurements with theoretical results Journal of Heat Transfer, Transactions ASME 120 1998 899 906
28. F.E. Pfefferkorn, F.P. Incropera, and Y.C. Shin Heat transfer model of semi-transparent ceramics undergoing laser-assisted machining International Journal of Heat and Mass Transfer 48 2005 1999 2012
29. X. Wu, H. Zhang, Y. Wang, Three-dimensional thermal analysis for laser assisted machining of ceramics using FEA, in: Proceedings of SPIE, Fourth International Symposium on Advanced Optical Manufacturing and Testing Technologies: Advanced Optical Manufacturing Technologies 7282, 2009, 72822I-1-5.
30. J.-F. Wu, Y.-B. Guu, Laser assisted machining methods and device, US Patent 7,002,100 B2, 2004.
31. M.C. Longo, Working piece by laser beam, US Patent 4,229,640, 1980.
32. S. Sun, J. Harris, and M. Brandt Parametric investigation of laser-assisted machining of commercially pure titanium Advanced Engineering Materials 10 2008 565 572
33. J.F. Gratias, L.J. Fan, G. Marot, P. Cohen, and A. Moisan Proposition of a method to optimize the machining of XC42 steel with laser assistance CIRP Annals 42 1993 115 118
34. W.B. Salem, G. Marot, A. Moisan, J.P. Longuemard, Laser assisted turning during finishing operation applied to hardened steels and Inconel 718, in: M. Geiger, F. Vollertsen (Eds.), Laser Assisted Net Shape Engineering, Proceedings of the LANE'94, vol. 1, Meisenbach Bamberg, 1994, pp. 455464.
35. Y.C. Shin, Laser assisted machining process with distributed lasers, US Patent 0062920 A1, 2007.
36. K. Armitage, Laser assisted machining of high chromium white cast iron, Thesis for Master of Engineering, Swinburne University of Technology, 2005.
37. J. Walter, R. Ritzi, Increasing tool life by laser assisted turning, in: M. Geiger, A. Otto (Eds.), Laser Assisted Net Shape Engineering 4, Proceedings of the LANE 2004, vol. 2, Meisenbach Bamberg, 2004, pp. 11571164.
38. B. Yang, and S. Lei Laser-assisted milling of silicon nitride ceramic: a machinability study International Journal of Mechatronics and Manufacturing Systems 1 2008 116 130
39. T. Thomas, J.O. Vigneau, Laser-assisted milling process, US Patent 5,906,459, 1999.
40. A. Demmer, S. Bausch, and K. Groll Perspectives for laser-assisted machining: cost-effective processing of difficult-to machine materials The Industrial Laser User 2005 38 41
41. Y. Tian, B. Wu, M. Anderson, and Y.C. Shin Laser-assisted milling of silicon nitride and Inconel 718 Journal of Manufacturing Science and Engineering, Transactions of the ASME 130 2008 031013-1-9
42. H. Hgel, M. Wiedmaier, T. Rudlaff, Laser processing integrated into machine tooldesign, applications, economy, in: M. Geiger, F. Vollertsen (Eds.), Laser Assisted Net Shape Engineering, Proceedings of the LANE'94, vol. 1, Meisenbach Bamberg, 1994, pp. 439453.
43. H. Hgel, M. Wiedmaier, and T. Rudlaff Laser processing integrated into machine tooldesign, applications, economy Optical and Quantum Electronics 27 1995 1149 1164
44. K. Krastel, and J. Drechsel Integration of laser processing in machine tools and their economy Proceedings of SPIE, Rapid Prototyping and Flexible Manufacturing 3102 1997 64 72
45. 3 ceramics planing International Journal of Machine Tools and Manufacture 47 2007 452 461
46. Y. Tian, and Y.C. Shin Laser-assisted burnishing of metals International Journal of Machine Tools and Manufacture 47 2007 14 22
47. Y. Tian, and Y.C. Shin Thermal modelling and experimental evaluation of laser-assisted dressing of superabrasive grinding wheels Proceedings of the Institution of Mechanical EngineersPart B: Journal of Engineering Manufacture 221 2007 605 616
48. C. Zhang, and Y.C. Shin A novel laser-assisted truing and dressing technique for vitrified CBN wheels International Journal of Machine Tools and Manufacture 42 2002 825 835
49. C. Zhang, and Y.C. Shin Wear of diamond dresser in laser assisted truing and dressing of vitrified CBN wheels International Journal of Machine Tools and Manufacture 43 2003 41 49
50. E. Westkmper Grinding assisted by Nd:YAG lasers CIRP Annals 44 1995 317 320
51. Q.M. Murphy, Apparatus and process for laser assisted drilling, US Patent 5,409,376, 1995.
52. P.A. Rebro, F.E. Pfefferkorn, Y.C. Shin, and F.P. Incropera Comparative assessment of laser-assisted machining for various ceramics Transactions of North American Manufacturing Research Institution 30 2002 153 160
53. M. Ignatiev, L. Okorokov, I. Smurov, V. Martino, G. Bertolow, and G. Flamant Laser assisted machining: process control based on real-time surface temperature measurements Journal De Physique 4 1994 C4-65-68
54. F.E. Pfefferkorn, J.C. Rozzi, F.P. Incropera, and Y.C. Shin Surface temperature measurement in laser-assisted machining processes Experimental Heat Transfer 10 1997 291 313
55. F.E. Pfefferkorn, F.P. Incropera, and Y.C. Shin Surface temperature measurement of semi-transparent ceramics by long-wavelength pyrometry Journal of Heat Transfer, Transactions ASME 125 2003 48 56
56. P.A. Rebro, Y.C. Shin, and F.P. Incropera Design of operating conditions for crackfree laser-assisted machining of mullite International Journal of Machine Tools and Manufacture 44 2004 677 694
57. Y. Tian, and Y.C. Shin Laser-assisted machining of damage-free silicon nitride parts with complex geometric features via in-process control of laser power Journal of the American Ceramic Society 89 2006 3397 3405
58. S. Skvarenina, and Y.C. Shin Laser-assisted machining of compacted graphite iron International Journal of Machine Tools and Manufacture 46 2006 7 17
59. Y. Tian, and Y.C. Shin Thermal modeling for laser-assisted machining of silicon nitride ceramics with complex features Journal of Manufacturing Science and Engineering, Transactions of the ASME 128 2006 425 434
60. J.C. Rozzi, F.P. Incropera, and Y.C. Shin Transient thermal response of rotating cylindrical silicon nitride workpiece subjected to translating laser heat source, Part II: parametric effects and assessment of a simplified model Journal of Heat Transfer, Transactions ASME 120 1998 907 915
61. J.C. Rozzi, F.E. Pfefferkorn, F.P. Incropera, and Y.C. Shin Transient, three-dimensional heat transfer model for the laser assisted machining of silicon nitride: I. Comparison of predictions with measured surface temperature histories International Journal of Heat and Mass Transfer 43 2000 1409 1424
62. J.C. Rozzi, F.P. Incropera, and Y.C. Shin Transient, three-dimensional heat transfer model for the laser assisted machining of silicon nitride: II. Assessment of parametric effects International Journal of Heat and Mass Transfer 43 2000 1425 1437
63. F.E. Pfefferkorn, Y.C. Shin, F.P. Incropera, and Y. Tian Laser-assisted machining of magnesia-partially-stabilized zirconia Journal of Manufacturing Science and Engineering, Transactions of the ASME 126 2004 42 51
64. N. Yang, M. Brandt, and S. Sun Numerical and experimental investigation of the heat-affected zone in a laser assisted machining of Ti6Al4V alloy process Materials Science Forum 618-619 2009 143 146
65. G. Germain, F. Morel, J.-L. Lebrun, and A. Morel Machinability and surface integrity for a bearing steel and a titanium alloy in laser assisted machining (optimisation on LAM on two materials) Lasers in Engineering 17 2007 329 344
66. X. Shen, S. Lei, Three-dimensional thermal analysis for laser assisted milling of silicon nitride ceramics using FEA, in: Proceedings of IMECE2005, 2005 ASME International Mechanical Engineering Congress and Exposition, Orlando, FL, USA, November 511, 2005.
67. C.R. Dandekar, Y.C. Shin, and J. Barnes Machinability improvement of titanium alloy (Ti-6Al-4V) via LAM and hybrid machining International Journal of Machine Tools and Manufacture 50 2010 174 182
68. R. Singh, M.J. Alberts, and S.N. Melkote Characterization and prediction of the heat-affected zone in a laser-assisted mechanical micromachining process International Journal of Machine Tools and Manufacture 48 2008 994 1004
69. A.N. Samant, and N.B. Dahotre Laser machining of structural ceramicsa review Journal of the European Ceramic Society 29 2009 969 993
70. P.A. Rebro, Y.C. Shin, and F.P. Incropera Laser-assisted machining of reaction sintered mullite ceramics Journal of Manufacturing Science and Engineering, Transactions of the ASME 124 2002 875 885
71. S. Lei, Y.C. Shin, and F.P. Incropera Deformation mechanisms and constitutive modeling for silicon nitride undergoing laser assisted machining International Journal of Machine Tools and Manufacture 40 2000 2213 2233
72. S. Lei, Y.C. Shin, and F.P. Incropera Experimental investigation of thermo-mechanical characteristics in laser assisted machining of silicon nitride ceramics Journal of Manufacturing Science and Engineering, Transactions of the ASME 123 2001 639 646
73. J.C. Rozzi, F.E. Pfefferkorn, Y.C. Shin, and F.P. Incropera Experimental evaluation of the laser assisted machining of silicon nitride ceramics Journal of Manufacturing Science and Engineering, Transactions of the ASME 122 2000 666 670
74. K.J. Bowman, F.E. Pfefferkorn, and Y.C. Shin Recrystallization textures during laser-assisted machining of zirconia ceramics Materials Science Forum 408412 2002 1669 1674
75. Y. Tian, and Y.C. Shin Multiscale finite element modeling of silicon nitride ceramics undergoing laser-assisted machining Journal of Manufacturing Science and Engineering, Transactions of the ASME 129 2007 287 295
76. F. Klocke, and T. Bergs Laser-assisted turning of advanced ceramics Proceedings of SPIE, Rapid Prototyping and Flexible Manufacturing 3102 1997 120 130
77. C. Chang, and C. Kuo Evaluation of surface roughness in LAM of aluminum oxide ceramics with Taguchi method International Journal of Machine Tools and Manufacturing 47 2007 141 147
78. B. Yang, X. Shen, and S. Lei Mechanisms of edge chipping in laser-assisted milling of silicon nitride ceramics International Journal of Machine Tools and Manufacture 49 2009 344 350
79. R.R. Boyer An overview on the use of titanium in the aerospace industry Materials Science and Engineering A213 1996 103 114
80. E.O. Ezugwu, J. Bonney, and Y. Yamane An overview of the machinability of aeroengine alloys Journal of Materials Processing Technology 134 2003 233 253
81. Z.G. Wang, Y.S. Wong, and M. Rahman High-speed milling of titanium alloys using binderless CBN tools International Journal of Machine Tools and Manufacture 45 2005 105 114
82. P.A. Dearnley, and A.N. Grearson Evaluation of principal wear mechanisms of cemented carbides and ceramics used for machining titanium alloy, IMI 318 Materials Science and Technology 2 1986 47 58
83. Z.G. Wang, M. Rahman, and Y.S. Wong Tool wear characteristics of binderless CBN tools used in high-speed milling of titanium alloys Wear 258 2005 752 758
84. H. Jiang, and R. Shivpuri A cobalt diffusion based model for predicting crater wear of carbide tools in machining titanium alloys Journal of Engineering Materials and Technology 127 2005 136 144
85. S. Zhang, J.F. Li, J.X. Deng, and Y.S. Li Investigation on diffusion wear during high-speed machining Ti-6Al-4V alloy with straight tungsten carbide tools International Journal of Advanced Manufacturing Technology 44 2009 17 55
86. E.O. Ezugwu, and Z.M. Wang Titanium alloys and their machinabilitya review Journal of Materials Processing Technology 68 1997 262 274
87. S. Sun, M. Brandt, and M.S. Dargusch Characteristics of cutting forces and chip formation in machining of titanium alloys International Journal of Machine Tools and Manufacture 49 2009 561 568
88. B. Lesourd, F.L. Matre, and T. Thomas The chip formation in conventional and laser assisted machiningapplication to the milling process Manufacturing Systems 24 1995 279 286
89. S. Sun, J. Harris, Y. Durandet, M. Brandt, Effect of laser beam on machining of titanium alloys, in: Proceedings of the Third Pacific International Conference on Application of Lasers and Optics, Beijing, China, 2008.
90. S. Sun, M. Brandt, M.S. Dargusch, The effect of a laser beam on chip formation during machining of Ti6Al4V alloy, Metallurgical and Materials Transactions A 41 (2010) 15731581.
91. J.E. Barnes, Y.C. Shin, M. Brandt, and S. Sun High speed machining of titanium alloys Materials Science Forum 618619 2009 159 163
92. G. Germain, F. Morel, J.-L. Lebrun, A. Morel, and B. Huneau Effect of laser assistance machining on residual stress and fatigue strength for a bearing steel (100Cr6) and a titanium alloy (Ti6Al4V) Materials Science Forum 524-525 2006 569 574
93. I.A. Choudhury, and M.A. El-Baradi Machinability of nickel-base super alloys: a general review Journal of Materials Processing Technology 77 1998 278 284
94. A. Devillez, F. Schneider, S. Dominiak, D. Dudzinski, and D. Larrouquere Cutting forces and wear in dry machining of Inconel 718 with coated carbide tools Wear 262 2007 931 942
95. G. Germain, J.L. Lebrun, T. Braham-Bouchnak, D. Bellett, and S. Auger Laser-assisted machining of Inconel 718 with carbide and ceramic inserts International Journal of Materials Forming Suppl. 1 2008 523 526
96. B. Shi, H. Attia, R. Vargas, and S. Tavakoli Numerical and experimental investigation of laser-assisted machining of Inconel 718 Machining Science and Technology 12 2008 498 513
97. Z.Y. Wang, K.P. Rajurkar, J. Fan, S. Lei, Y.C. Shin, and G. Petrescu Hybrid machining of Inconel 718 International Journal of Machine Tools and Manufacture 43 2003 1391 1396
98. W. Knig, A.K. Zaboklicki, Laser-asisted hot machining processes: technological potentials, in: M. Geiger, F. Vollertsen (Eds.), Laser Assisted Net Shape Engineering, Proceedings of the LANE'94, vol. 1, Meisenbach Bamberg, 1994, pp. 389404.
99. T. Weinert Relation between process energy and tool wear when turning harfacing alloys CIRP Annals 43 1994 97 100
100. Y. Jeon, and F. Pfefferkorn Effect of laser preheating the workpiece on micro end milling of metals Journal of Manufacturing Science and Engineering, Transactions of the ASME 130 2008 011004-1-9
101. A.K.M.N. Amin, I. Abraham, N. Khairusshima, and M.I. Ahmed Influence of preheating on performance of circular carbide inserts in end milling of carbon steel Journal of Materials Processing Technology 185 2007 97 105
102. G. Germain, J.-L. Lebrun, P. Robert, P.D. Santo, and A. Poitou Experimental and numerical approaches of laser assisted turning International Journal of Forming Processes 8 2005 347 361
103. E. Kannatey-Asibu Principles of Laser Materials Processing 2009 John Wiley & Sons, Inc. Hoboken pp. 489491
104. Z.F. Zhang, L.C. Zhang, and Y.W. Mai Wear of ceramic particle-reinforced metalmatrix composites: Part I. Wear mechanism Journal of Materials Science 30 1995 1961 1966
105. A. Pramanik, L.C. Zhang, and J.A. Arsecularatne Machining of metal matrix composites: effect of ceramic particles on residual stress, surface roughness and chip formation International Journal of Machine Tools and Manufacture 48 2008 1613 1625
106. M. El-Gallab, and M. Sklad Machining of Al/SiC particulate metalmatrix composites, Part I: Tool performance Journal of Materials Processing Technology 83 1998 151 158 (Pubitemid 128408295)
107. A. Manna, and B. Bhattacharyya A study on different tooling systems during machining of Al/SiC-MMC Journal of Materials Processing Technology 123 2002 476 482
108. S. Kannan, and H.A. Kishawy Tribological aspects of machining aluminium metal matrix composites Journal of Materials Processing Technology 198 2008 399 406
109. A. Pramanik, L.C. Zhang, and J.A. Arsecularatne Prediction of cutting forces in machining of metal matrix composites International Journal of Machine Tools and Manufacture 46 2006 1795 1803
110. 3 particle reinforced aluminum matrix composite Journal of Materials Processing Technology 129 2002 268 272
111. S. Barnes, I.R. Pashby, and D.K. Mok The effect of workpiece temperature on the machinability of an aluminum/SiC MMC Journal of Manufacturing Science and Engineering, Transactions of the ASME 118 1996 422 427
112. F.E. Pfefferkorn, S. Lei, Y. Jeon, and G. Haddad A metric for defining the energy efficiency of thermally assisted machining International Journal of Machine Tools and Manufacture 49 2009 357 365
113. R. Komanduri, M. Lee, D.G. Flom, R.A. Thompson, M.G. Jones, R.J. Douglas, Pulsed laser pretreated machining, US Patent 4,356,376, 1982.
114. M. Kaiser, Thermalmechanical modeling of laser ablation hybrid machining, Ph.D. Thesis, Texas Tech University, 2001.
115. S. Barnes, R. Morgan, and A. Skeen Effect of laser pre-treatment on the machining performance of aluminum/SiC MMC Journal of Engineering Materials and Technology 125 2003 378 384