Thermal Modeling for Laser-Assisted Machining of Silicon Nitride Ceramics with Complex Features

2005 ◽  
Vol 128 (2) ◽  
pp. 425-434 ◽  
Author(s):  
Yinggang Tian ◽  
Yung C. Shin
Keyword(s):  
Silicon Nitride ◽  
Thermal Model ◽  
Three Dimensional ◽  
Infrared Camera ◽  
Ceramic Materials ◽  
Industrial Applications ◽  
Laser Assisted Machining ◽  
Nitride Ceramics ◽  
Complex Features ◽  
Fabrication Costs

The feasibility of laser-assisted machining (LAM) and its potential to significantly reduce fabrication costs and improve product quality have been shown experimentally for various ceramic materials. However, no systematical investigation has been performed to expand LAMs capability to parts with complex features, although such capability is essential for industrial applications. This paper presents a transient, three-dimensional thermal model developed for LAM of workpieces with complex geometric features and its validation by in-process surface temperature measurements with an infrared camera. It is shown that the LAM experiments designed based on the predictions by the thermal model successfully produced silicon nitride parts with complex features, thus demonstrating the capabilities of LAM in fabricating ceramic parts suitable for industrial implementation.

Laser-Assisted Milling of Silicon Nitride Ceramics

2006 ◽  
Author(s):  
Yinggang Tian ◽  
Benxin Wu ◽  
Yung C. Shin
Keyword(s):  
Silicon Nitride ◽  
Thermal Model ◽  
Three Dimensional ◽  
Infrared Camera ◽  
Ceramic Materials ◽  
Good Surface ◽  
Milling Operations ◽  
Nitride Ceramics ◽  
Good Surface Roughness ◽  
Coated Carbide

Laser-assisted machining (LAM) has shown its potential to significantly reduce fabrication costs and improve product quality for advanced ceramic materials. While extensive studies have been conducted on laser-assisted turning (LAT) of various ceramics, few attempts have been made to extend LAM to milling operations. In this paper, a transient, three-dimensional thermal model is developed for laser-assisted milling (LAML) and verified by surface temperature measurements with an infrared camera. LAML experiments designed by the model are successfully conducted on silicon nitride ceramics using TiAIN coated carbide end mills. The promising experimental results, including good surface roughness and acceptable tool wear, show the validation of applying the thermal model to design LAML processes and the feasibility of employing LAML to advanced ceramics.

Laser-Assisted Milling of Silicon Nitride Ceramics and Inconel 718

2008 ◽  
Vol 130 (3) ◽  
Author(s):  
Yinggang Tian ◽  
Benxin Wu ◽  
Mark Anderson ◽  
Yung C. Shin
Keyword(s):  
Silicon Nitride ◽  
Inconel 718 ◽  
Thermal Model ◽  
Cutting Tools ◽  
Three Dimensional ◽  
Infrared Camera ◽  
Advanced Materials ◽  
Good Surface ◽  
Nitride Ceramics ◽  
Coated Carbide

Laser-assisted machining (LAM) has shown its potential to significantly reduce fabrication costs and improve product quality for advanced materials. While extensive studies have been conducted on laser-assisted turning of various ceramics and high temperature alloys, few attempts have been made to extend LAM to milling operations. In this paper, a transient, three-dimensional thermal model developed for laser-assisted milling (LAML) is presented and its accuracy is verified by surface temperature measurements with an infrared camera. LAML experiments designed by the model are successfully conducted on silicon nitride ceramics using TiAlN coated carbide end mills and Inconel 718 using SiC reinforced alumina cutting tools. The promising experimental results, including good surface roughness and acceptable tool wear, show the validation of applying the thermal model to design LAML processes and the feasibility of employing LAML for difficult-to-machine materials such as advanced ceramics and superalloys.

Progress in Silicon Nitride Ceramics in Japan

1992 ◽  
Vol 287 ◽  
Author(s):  
K. Komeya
Keyword(s):  
Silicon Nitride ◽  
Cost Reduction ◽  
Industrial Applications ◽  
Powder Synthesis ◽  
Materials Development ◽  
Nitride Ceramics ◽  
Government Project ◽  
Three Stages ◽  
The Government ◽  
Fine Ceramics

ABSTRACTProgress in silicon nitride ceramics in Japan is reviewed. It is historically divided into three stages. Through these stages, basic experimental research and innovations have progressed along with industrial applications, and the government project on fine ceramics in 1981-1992 has contributed much to the acceleration in the development of silicon nitride ceramics. Focus in this paper is mainly on materials development including raw powder synthesis and exploration for applications. The future prospect of utilizing silicon nitride as an engineering material, however, is seen to depend on cost reduction and reliability improvement.

Experimental Investigation of Thermo-Mechanical Characteristics in Laser-Assisted Machining of Silicon Nitride Ceramics

1999 ◽  
Author(s):  
Shuting Lei ◽  
Yung C. Shin ◽  
Frank P. Incropera
Keyword(s):  
Silicon Nitride ◽  
Tool Wear ◽  
Material Removal ◽  
Mechanical Characteristics ◽  
Surface Damage ◽  
Workpiece Temperature ◽  
Laser Assisted Machining ◽  
Nitride Ceramics ◽  
On Line ◽  
Extent Of Damage

Abstract Laser-assisted machining (LAM) of silicon nitride (Si3N4) is evaluated for its potential to become an economically viable process in fabricating precision ceramic parts. On-line measurements of cutting force and workpiece temperature are performed, and tool wear and surface integrity are examined. Tool wear characteristics are determined as a function of workpiece temperature, which is measured on-line using a laser pyrometer. Tool wear/failure mechanisms are characterized using optical microscopy, while application of scanning electron microscopy to heated and machined surfaces, as well as to chips, is used to infer material removal mechanisms and the extent of damage caused by LAM. The sub-surface damage of parts produced by LAM is compared with that of typical ground parts.

Simulation and Experimental Study on Temperature Fields for Laser Assisted Machining of Silicon Nitride

2009 ◽  
Vol 419-420 ◽  
pp. 521-524
Author(s):  
Xue Feng Wu ◽  
Hong Zhi Zhang ◽  
Yang Wang ◽  
Chao Xie
Keyword(s):  
Silicon Nitride ◽  
Laser Heating ◽  
Laser Power ◽  
Three Dimensional ◽  
Temperature Fields ◽  
Transfer Model ◽  
Beam Diameter ◽  
Power Laser ◽  
Laser Assisted Machining ◽  
Translational Speed

Laser assisted machining (LAM) is an effective method machining difficult-to-machine materials such as ceramics which uses a high power laser to focally heat a workpiece prior to material removal with a traditional cutting tool. A laser assisted machining experiment system was set up and a transient, three-dimensional heat transfer model was developed for LAM of silicon nitride using Finite Element Method to understand the thermal process of laser heating. The model was based on temperature-dependent thermophysical properties and the heat generated was neglected due to cutting which is assumed to be small compared to the heat generated by laser heating. The experiments were carried out to investigate the effects of operating parameters, such as laser power, laser translational speed, rotational speed, laser beam diameter and preheating time on temperature distribution. An infrared radiation thermometer was used to measure the surface temperature histories and the experimental results were in good agreement with predictions. The laser power and laser translational speed have the greatest influence on the temperature.

Microstructural Modeling and Dynamic Process Simulation of Laser-Assisted Machining of Silicon Nitride Ceramics With Distinct Element Method

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
Xinwei Shen ◽  
Budong Yang ◽  
Shuting Lei
Keyword(s):  
Silicon Nitride ◽  
Dynamic Process ◽  
Distinct Element ◽  
Subsurface Damage ◽  
Distinct Element Method ◽  
Laser Assisted Machining ◽  
Nitride Ceramics ◽  
Chip Size ◽  
Distinct Element Code ◽  
Element Method

The distinct element method (or discrete element method, DEM) is applied to simulate the dynamic process of laser-assisted machining (LAM) of silicon nitride ceramics. This is motivated by the fact that LAM of ceramics shows a few complicated characteristics such as spontaneous crack formation, discontinuous chips, etc. Thus, using the two-dimensional distinct element code, PFC2D, the microstructure of a β-type silicon nitride ceramic is modeled, and the resulting temperature-dependent synthetic specimens are created first, and then, machining simulations are conducted. The DEM model is validated through comparing the predicted results with those from the experiments under different cutting temperatures in terms of cutting force, chip size, and depth of subsurface damage. Furthermore, the mechanisms of LAM are analyzed from the aspects of material removal, chip segments, surface/subsurface damage, as well as crack initiation, propagation, and coalescence.

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