Experimental and numerical study of low frequency pulsed Nd:YAG laser heating of slip cast fused silica ceramics for laser assisted turning process considering laser beam overlapping

Document Type : Article

Authors

1 Department of Mechanical Engineering, Sharif University of Technology, Tehran, Iran

2 Department of Materials Science, Malek-Ashtar University, ShahinShahr, Iran

Abstract

Machining of ceramics often involves many challenges due to their high hardness, brittleness, and low thermal conductivity. Laser assisted machining (LAM) is a promising technology for improving the machinability of hard-to-cut materials. In this work, the effect of laser heating in the LAM process on slip cast fused silica (SCFS) ceramics is investigated by presenting a numerical thermal analysis of laser effects on material behavior. A transient three-dimensional heat transfer analysis for laser assisted turning (LAT) of SCFS is performed using finite element method. Temperature distributions in SCFS cylindrical specimens are obtained. Moreover, the influence of laser parameters such as power, translational speed, and feed rate on the temperature field are studied. To increase the absorptivity of the ceramic surface, a coating is applied, and the absorptivity of the coated surface is determined by carrying out a series of experiments. Experiments are performed to validate the numerical transient heat transfer finite element model. In addition, the effects of spot overlapping of pulsed laser on temperature distribution and absorptivity of SCFS workpiece are studied. It is for the first time that effect of laser beam overlapping on low frequency pulsed laser heating in LAT is formulated and completely investigated.

Keywords

Main Subjects


References:
1. Westkamper, E. "Grinding assisted by Nd:YAG lasers", CIRP Ann-Manuf. Techn., 44(1), pp. 317-320 (1995).
2. Tian, Y., Wu, B., Anderson, M., and Shin, Y.C. "Laser-assisted milling of silicon nitride ceramics and inconel 718", J. Manuf. Sci. Eng., 130(3), pp. 031013- 031013 (2008).
3. Wiedenmann, R. and Zaeh, M.F. "Laser-assisted milling-process modeling and experimental validation", CIRP J. of Manuf. Sci. and Tech., 8, pp. 70-77 (2015).
4. Lei, S., Shin, Y.C., and Incropera, F.P. "Experimental investigation of thermo-mechanical characteristics in laser-assisted machining of silicon nitride ceramics", J. Manuf. Sci. Eng., 123(4), pp. 639-646 (2000).
5. Bejjani, R., Shi, B., Attia, H., and Balazinski, M. "Laser assisted turning of Titanium metal matrix composite", CIRP Ann-Manuf. Techn., 60(1), pp. 61- 64 (2011).
6. Rebro, P.A., Shin, Y.C., and Incropera, F.P. "Laserassisted machining of reaction sintered mullite ceramics", J. Manuf. Sci. Eng., 124(4), pp. 875-885 (2002).
7. Germain, G., Dal Santo, P., and Lebrun, J.L. "Comprehension of chip formation in laser assisted machining", Int. J. Mach. Tool. Manufact., 51(3), pp. 230-238 (2011).
8. Zhang, G., Jiang, C., Zhang, S., Wang, Y., Chen, X., and Yu, L. "An experimental investigation of laser assisted drilling process", Mater. Res. Innov., 19(sup8), pp. S8-889-S888-894 (2015).
9. Chang, C.-W. and Kuo, C.-P. "An investigation of laser-assisted machining of Al2O3 ceramics planing", Int. J. Mach. Tool. Manufact., 47(3-4), pp. 452-461 (2007).
10. Rebro, P.A., Shin, Y.C., and Incropera, F.P. "Design of operating conditions for crackfree laser-assisted machining of mullite", Int. J. Mach. Tool. Manufact., 44(7), pp. 677-694 (2004).
11. Chang, C.-W. and Kuo, C.-P. "Evaluation of surface roughness in laser-assisted machining of aluminum oxide ceramics with Taguchi method", Int. J. Mach. Tool. Manufact., 47(1), pp. 141-147 (2007).
12. Tian, Y. and Shin, Y.C. "Thermal modeling for laserassisted machining of silicon nitride ceramics with complex features", J. Manuf. Sci. Eng., 128(2), pp. 425-434 (2005).
13. Kim, J.-D., Lee, S.-J., and Suh, J. "Characteristics of laser assisted machining for silicon nitride ceramic according to machining parameters", J. Mech. Sci. Technol., 25(4), pp. 995-1001 (2011).
14. Pfefferkorn, F.E., Shin, Y.C., Tian, Y., and Incropera, F.P. "Laser-assisted machining of magnesia-partiallystabilized zirconia", J. Manuf. Sci. Eng., 126(1), pp. 42-51 (2004).
15. Pfefferkorn, F.E., Lei, S., Jeon, Y., and Haddad, G. "A metric for defining the energy efficiency of thermally assisted machining", Int. J. Mach. Tool. Manufact., 49(5), pp. 357-365 (2009).
16. Rozzi, J.C., Pfefferkorn, F.E., Shin, Y.C., and Incropera, F.P. "Experimental evaluation of the laser assisted machining of silicon nitride ceramics", J. Manuf. Sci. Eng., 122(4), pp. 666-670 (1999).
17. Tian, Y. and Shin, Y.C. "Multiscale finite element modeling of silicon nitride ceramics undergoing laserassisted machining", J. Manuf. Sci. Eng., 129(2), pp. 287-295 (2006).
18. Dong, X. and Shin, Y.C. "Multiscale finite element modeling of alumina ceramics undergoing laserassisted machining", J. Manuf. Sci. Eng., 138(1), p. 011004 (2016).
19. Rozzi, J.C., Pfefferkorn, F.E., Incropera, F.P., and Shin, Y.C. "Transient thermal response of a rotating cylindrical silicon nitride workpiece subjected to a translating laser heat source, Part I: comparison of surface temperature measurements with theoretical results", J. Heat Transfer., 120(4), pp. 899-906 (1998).
20. Rozzi, J.C., Incropera, F.P., and Shin, Y.C. "Transient thermal response of a rotating cylindrical silicon nitride workpiece subjected to a translating laser heat source, Part II: Parametric effects and assessment of a simplified model", J. Heat Transfer., 120(4), pp. 907- 915 (1998).
21. Rozzi, J.C., Incropera, F.P., and Shin, Y.C. "Transient, three-dimensional heat transfer model for the laser assisted machining of silicon nitride: II. Assessment of parametric effects", Int. J. Heat Mass Transfer., 43(8), pp. 1425-1437 (2000).
22. Rozzi, J.C., Pfefferkorn, F.E., Incropera, F.P., and Shin, Y.C. "Transient, three-dimensional heat transfer model for the laser assisted machining of silicon nitride: I. Comparison of predictions with measured surface temperature histories", Int. J. Heat Mass Transfer.,43(8), pp. 1409-1424 (2000). 
23. Pfefferkorn, F.E., Incropera, F.P., and Shin, Y.C. "Heat transfer model of semi-transparent ceramics undergoing laser-assisted machining", Int. J. Heat Mass Transfer., 48(10), pp. 1999-2012 (2005).
24. Smith, D.G. and Chowdary, M. "The fracture toughness of slip-cast fused silica", Mater. Sci. Eng., 20, pp. 83-88 (1975).
25. Harris, J.N. and Welsh, E.A., Fused Silica Design Manual, Defense Technical Information Center (1973).
26. Roostaei, H. and Movahhedy, M.R. "Analysis of heat transfer in laser assisted machining of slip cast fused silica ceramics", Proc. CIRP., 46, pp. 571-574 (2016).
27. Huang, L.-J., Li, B.-J., and Ren, N.-F. "Enhancing optical and electrical properties of Al-doped ZnO coated polyethylene terephthalate substrates by laser annealing using overlap rate controlling strategy", Ceram. Int., 42(6), pp. 7246-7252 (2016).
28. Hafiz, A.M.K., Bordatchev, E.V., and Tutunea-Fatan, R.O. "Influence of overlap between the laser beam tracks on surface quality in laser polishing of AISI H13 tool steel", J. Manuf. Process., 14(4), pp. 425- 434 (2012).
29. Hu, Y.X. and Yao, Z.Q. "Fem simulation of residual stresses induced by laser shock with overlapping laser spots", Acta Metall. Sin. (Engl. ED), 21(2), pp. 125- 132 (2008).
30. Samant, A.N. and Dahotre, N.B. "Three-dimensional laser machining of structural ceramics", J. Manuf. Process., 12(1), pp. 1-7 (2010).
31. Kuar, A., Doloi, B., and Bhattacharyya, B. "Modelling and analysis of pulsed Nd: YAG laser machining characteristics during micro-drilling of zirconia (ZrO 2)", Int. J. Mach. Tool. Manufact., 46(12), pp. 1301- 1310 (2006).
32. Dahotre, N.B. and Harimkar, S., Laser Fabrication and Machining of Materials, Springer Science & Business Media (2008).
33. Mohanty, A.K., Tawfek, A.A., and Prasad, B.V.S.S.S. "Heat transfer from a rotating cylinder in cross flow", Exp. Therm. Fluid Sci., 10(1), pp. 54-61 (1995).
34. Bohn, M. and Wang, K.-Y., Experiments and Analysis on the Molten-Salt Direct-Contact Absorption Receiver Concept, in, Solar Energy Research Inst., Golden, CO, USA (1986).
35. Fleming, J., Fused Silica Manual, Georgia Inst. of Tech., Atlanta. Engineering Experiment Station (1964).