Experimental Study of Micromachining on Borosilicate Glass Using CO2 Laser

2020 ◽  
Vol 143 (5) ◽  
Author(s):  
Vishnu Vardhan Posa ◽  
Murali Sundaram
Keyword(s):  
Laser Scanning ◽  
Laser Energy ◽  
Removal Rate ◽  
Scanning Speed ◽  
Machining Process ◽  
Laser Machining ◽  
Glass Work ◽  
Workpiece Material ◽  
Laser Parameters ◽  
Wide Range

Abstract Laser beam machining (LBM) is a versatile process that can shape a wide range of engineering materials such as metals, ceramics, polymers, and composite materials. However, machining of glass materials by LBM is a challenge as most of the laser energy is not absorbed by the surface. In this study, an attempt has been made to increase the absorptivity of the glass material by using a coating on the surface of the material. Glass has been used in this study because of its extensive applications in the micro-opto-electro-mechanical systems. The optimal machining depends on both laser parameters and properties of the workpiece material. There are number of laser parameters that can be varied in the laser machining process. It is difficult to find optimal laser parameters due to the mutual interaction of laser parameters. A statistical study based on design of experiment (DoE) has been made to study the effect of coating and parameters like laser power, laser scanning speed, angle of inclination of the workpiece on depth of the slot, width of the slot, aspect ratio, and material removal rate (MRR) in the laser machining process using 2k factorial design and analysis of variance (ANOVA). On an average, four times increase in depth of the slot, two times increase in width of the slot and seven times increase in the MRR were observed in the glass samples with coating when compared to uncoated glass work samples.

Experimental Study of Micromachining on Reflective Surface Using CO2 Laser

2020 ◽  
Author(s):  
Vishnu Vardhan Posa ◽  
Murali Sundaram
Keyword(s):  
Laser Beam ◽  
Material Removal ◽  
Machining Process ◽  
Laser Machining ◽  
Glass Work ◽  
Workpiece Material ◽  
Laser Beam Machining ◽  
Laser Parameters ◽  
Reflective Coating ◽  
Work Samples

Abstract Laser Beam Machining (LBM) is one of the versatile non-traditional manufacturing processes. Material removal in LBM is based on high heat flux generated by laser beam which melts and vaporizes the workpiece material in the focused point. Laser Beam Machining process can shape almost all range of engineering materials from metallic alloys to non-metallic alloys as well as composite materials. But one of the main limitations of laser beam machining is the machining of reflective materials. When laser beam is focused on the reflective surface, part of the energy is reflected by the surface and the remaining is absorbed. In this study, an attempt has been made to increase the absorptivity of the reflective material by coating anti-reflective coating on the surface of the material. Glass has been used as reflective material in this study because of its extensive applications in the micro-opto-electro-mechanical systems. The optimal machining depends on both laser parameters and properties of the workpiece material. There are number of laser parameters that can be varied in the laser machining process. It is difficult to find optimal laser parameters due to mutual interaction of laser parameters. A statistical study based on design of experiment (DoE) has been made to study the effect of anti-reflective coating and parameters like laser power, laser scanning speed, angle of inclination of the workpiece on depth of the slot, width of the slot, aspect ratio and material removal rate (MRR) in the laser machining process using 2k factorial design and ANOVA. On an average 4 times increase in depth of the slot, 2 times increase in width of the slot and 7 times increase in the MRR was observed in the glass work samples with anti-reflective coating when compared to glass work samples without anti-reflective coating.

Role of energy consumption, cutting tool and workpiece materials towards environmentally conscious machining: A comprehensive review

2019 ◽  
Vol 234 (3) ◽  
pp. 335-354 ◽  
Author(s):  
Salman Pervaiz ◽  
Sathish Kannan ◽  
Ibrahim Deiab ◽  
Hossam Kishawy
Keyword(s):  
Energy Consumption ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process ◽  
Machining Process ◽  
Workpiece Material ◽  
Tool Materials ◽  
Wide Range ◽  
Cutting Operation

Metal-cutting process deals with the removal of material using the shearing operation with the help of hard cutting tools. Machining operations are famous in the manufacturing sector due to their capability to manufacture tight tolerances and high dimensional accuracy while simultaneously maintaining the cost-effectiveness for higher production levels. As metal-cutting processes consume a great amount of input resources and generate some material-based waste streams, these processes are highly criticized due to their high and negative environmental impacts. Researchers in the metal-cutting sector are currently exploring and benchmarking different activities and best practices to make the cutting operation environment friendly in nature. These eco-friendly practices mainly cover the wide range of activities directly or indirectly associated with the metal-cutting operation. Most of the literature for sustainable metal-cutting activities revolves around the sustainable lubrication techniques to minimize the negative influence of cutting fluids on the environment. However, there is a need to enlarge the assessment domain for the metal-cutting process and other directly and indirectly associated practices such as enhancing sustainability through innovative methods for workpiece and cutting tool materials, and approaches to optimize energy consumption should also be explored. The aim of this article is to explore the role of energy consumption and the influence of workpiece and tool materials towards the sustainability of machining process. The article concludes that sustainability of the machining process can be improved by incorporating different innovative approaches related to the energy and tool–workpiece material consumptions.

Laser-Energy-Density Dependent Formation of Al2O3-TiC Coating by Laser-Assisted Combustion

2014 ◽  
Vol 941-944 ◽  
pp. 2182-2189
Author(s):  
Cai Xuan Lu ◽  
He Ping Li ◽  
Peng Chen ◽  
You Wei Yan
Keyword(s):  
Energy Density ◽  
Powder Mixture ◽  
Laser Scanning ◽  
Laser Energy ◽  
Steel Substrate ◽  
Composite Ceramic ◽  
Scanning Speed ◽  
Ceramic Coatings ◽  
Medium Carbon Steel ◽  
Laser Energy Density

Al2O3-TiC composite ceramic coatings were obtained by laser-assisted combustion. Al-TiO2-C precursor powder mixture was coated on a medium-carbon steel substrate. When a laser scanned on the powder mixture, it went through combustion synthesis reaction triggered by the incident laser beam and formed the target products. The microstructure of the obtained coatings with different laser processing parameters was characterized using field emission scanning electron microscopy. The laser energy density, controlled by changing laser power and laser scanning speed, was found to play an important role on the microstructure of the products. The formation mechanism of different micro-morphologies with different laser energy densities was proposed according to thermodynamic calculation.

Multi-objective optimization of process parameters involved in micro-finishing of Al/SiC MMCs by abrasive flow machining process

2016 ◽  
Vol 232 (4) ◽  
pp. 319-332 ◽  
Author(s):  
Mittal Sushil ◽  
Kumar Vinod ◽  
Kumar Harmesh
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Removal Rate ◽  
Fluid Pressure ◽  
Base Material ◽  
Machining Process ◽  
Workpiece Material ◽  
Abrasive Flow Machining ◽  
Optimization Of Process Parameters ◽  
Desirability Approach

It is hard to finish small slots in composite materials which have wide applications nowadays in aerospace, automobile and medical. Abrasive flow machining is a process that is suitable for such type of operations. In this paper, by using abrasive flow machining, investigation of SiC Metal Matrix Composites (MMCs) with aluminum as base material has been done. Material removal rate and change in surface roughness (ΔRa) are taken as response parameters. Response surface methodology has been applied to find out the effect of input parameters like fluid pressure, percentage of oil in media, grit size, concentration of abrasives, workpiece material and number of cycles on response parameters. Box–Behnken design has been preferred. Response parameters have been optimized using the desirability approach in response surface methodology. The significance of different parameters is identified using analysis of variance. An optimum combination of parameters is designed for the process. Furthermore, specimens were examined and analyzed using scanning electron microscope and X-ray diffraction techniques.

scholarly journals Cutting Parameter Optimization in Finishing Milling of Ti-6Al-4V Titanium Alloy under MQL Condition using TOPSIS and ANOVA Analysis

2021 ◽  
Vol 11 (1) ◽  
pp. 6775-6780
Author(s):  
V. C. Nguyen ◽  
T. D. Nguyen ◽  
D. H. Tien
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Titanium Alloys ◽  
Contact Area ◽  
Removal Rate ◽  
Multiple Criteria Decision Making ◽  
Machining Process ◽  
Anova Analysis ◽  
Wide Range ◽  
Cutting Parameter Optimization

Titanium and its alloys give immense specific strength, imparting properties such as corrosion and fracture resistance, making them the right candidate for medical and aerospace applications. There is a wide range of engineering applications that use titanium alloys in a variety of forms. The cost of these alloys is slightly higher in comparison to other variants due to the problematic extraction of the molten process. To reduce costs, titanium alloy products could be made by casting, isothermal forging, radial swaging, or powder metallurgy, although these techniques require some kind of finishing machining process. Titanium and its alloys are difficult to machine due to skinny chips leading to a small cutting tool-workpiece contact area. The thermal conductivity of titanium alloys is too low and the stress produced is too large due to the small contact area, which results in very high cutting temperatures. This paper deals with the experimental study of the influence of the Minimum Quantity Lubricant (MQL) environment in the milling of Ti-6Al-4V alloy considering the optimization of surface roughness and production rate. Taguchi-based TOPSIS and ANOVA were used to analyze the results. The experimental results show that MQL with vegetable oil is successfully applied in the milling of Ti-6Al-4V. The research confirms the suitability of TOPSIS in solving the Multiple Criteria Decision Making (MCDM) issue, by choosing the best alternative at Vc=120m/min, fz=0.065mm/tooth, and ap=0.2mm, where the surface roughness and material removal rate are 0.41µm and 44.1492cm3/min respectively. Besides, ANOVA can be used to predict the best parameters set in the milling process based on the regression model. The parameters predicted by ANOVA analysis do not coincide with any implemented parameters

Electrical arc machining: Process capabilities and current research trends

2019 ◽  
Vol 233 (15) ◽  
pp. 5190-5200 ◽  
Author(s):  
Pankaj Kumar Shrivastava ◽  
Shrihar Pandey ◽  
Shivam Dangi
Keyword(s):  
Removal Rate ◽  
Machining Process ◽  
Advanced Materials ◽  
Future Research ◽  
Machining Processes ◽  
Workpiece Material ◽  
Electrical Arc ◽  
Control Factors ◽  
Conductive Ceramics ◽  
Unconventional Machining

Electrical arc machining is the thermal energy-based unconventional machining process, which utilizes energy of arc to melt and vaporize workpiece material. Electrical arc machining has the capability to machine advanced materials such as metal matrix composites, superalloys, and conductive ceramics effectively. The process is considered to be efficient than most of the other unconventional machining processes in terms of the material removal rate. But it has got limitations because it results in a very poor surface finish. Tool wear rate, recast layer formation, surface and subsurface cracks, and geometrical inaccuracy are other limitations up to a certain extent. In this paper, the comprehensive review of research carried out so for in the area of electrical arc machining has been presented. The paper discusses the detailed experimental and theoretical studies done on electrical arc machining to elucidate the effects of various input control factors on different quality characteristics. The paper also contains modeling and optimization studies done so far in electrical arc machining and finally discusses the future research possibilities in the area.

Bubble Formation in the Underwater Laser Ablation of Silicon

2016 ◽  
Vol 835 ◽  
pp. 144-148 ◽  
Author(s):  
Wisan Charee ◽  
Viboon Tangwarodomnukun ◽  
Chaiya Dumkum
Keyword(s):  
Laser Beam ◽  
High Speed ◽  
Bubble Formation ◽  
Laser Pulses ◽  
Machining Process ◽  
Laser Machining ◽  
Dynamic Features ◽  
Workpiece Material ◽  
Work Surface ◽  
Underwater Laser

Thermal damage of workpiece material induced by laser machining process can be reduced by using the underwater technique. This method requies the whole workpiece to be submerged in water while a laser beam strikes the work surface for ablation. Though water can cool the workpiece during the ablation, the dynamic features of water can adversely interfere the laser beam. The vapor bubbles created in water can scatter the laser beam and in turn attenuate the laser intensity at the work surface so as the ablation performance. In this paper, the bubble formation caused by laser machining of silicon in water was investigated and analyzed. The shadowgraph technique associated with the high speed camera was used to capture and measure the vapor bubble in water. The bubble size was found to increase with the laser pulse energy. After a number of laser pulses irradiated on the workpiece surface, the bubble was broken up into small ones which can significantly disturb the laser beam so as the ablation performance.

Study on Compound Machining of Polyurethane Polishing Pad and Cluster Abrasive Brush Based on MR Effect

2011 ◽  
Vol 487 ◽  
pp. 238-242 ◽  
Author(s):  
Min Li ◽  
Qiu Sheng Yan ◽  
Jia Bin Lu ◽  
Jing Fu Chai
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Parameters ◽  
Polishing Process ◽  
Workpiece Material ◽  
Crystal Silicon ◽  
Polishing Pad ◽  
Mr Effect

Method of compound machining is used to process single crystal silicon and SrTiO3 ceramic substrates, and the factors on effects of compound machining are studied such as magnetic field intensity, processing time, rotating speed of lapping plate and lapping pressure. The results show that the roughness of work pieces processed by compound machining are smaller than that by lapping based on cluster MR effect and polyurethane pad polishing process, while the material removal rate is higher than polyurethane pad polishing process, therefore, compound machining shows its synergistic effect between lapping based on cluster MR effect and polyurethane pad polishing process. The type and properties of workpiece material, and machining parameters both have a significant impact on the roughness and material removal rate of compound machining process of polyurethane polishing pad and cluster abrasive brush based on MR effect.

Study on Rules in Material Removal Rate and Surface Quality of Short Electric Arc Machining Process

2008 ◽  
Vol 33-37 ◽  
pp. 1313-1318 ◽  
Author(s):  
Jian Ping Zhou ◽  
Chu Hua Liang ◽  
Wen Jing Teng ◽  
Yan Xu ◽  
Bi Sheng Zhou
Keyword(s):  
Low Voltage ◽  
Removal Rate ◽  
Orthogonal Experiment ◽  
Electric Arc ◽  
Machining Process ◽  
Machining Efficiency ◽  
Workpiece Material ◽  
Process Indicators ◽  
Mixed Medium

Short electric arc machining (SEAM) is a non-conventional machining process that utilizes an arc to melt and vaporize workpiece material. A low voltage, high current supply is employed to produce a continuous arc in either a water-air mixed medium or in air. This paper describes an investigation into the optimization of the SEAM machining efficiency based on experimental design which considers both electrical parameters and machine parameters. The work uses the orthogonal experiment processes to research the influence of the process indicators on machining efficiency.

2-D Path Planning for Direct Laser Deposition Process

2010 ◽  
Author(s):  
Swathi Routhu ◽  
Divya Kanakanala ◽  
Jianzhong Ruan ◽  
Xiaoqing Frank Liu ◽  
Frank Liou
Keyword(s):  
Laser Scanning ◽  
Tool Path ◽  
Scanning Speed ◽  
Deposition Process ◽  
Metal Deposition ◽  
Machining Process ◽  
Machining Processes ◽  
Direct Laser ◽  
Deposition Processes ◽  
Deposition Height

The zigzag and offset path have been the two most popular path patterns for tool movement in machining process. Different from the traditional machining processes, the quality of parts produced by the metal deposition process is much more dependent upon the choice of deposition paths. Due to the nature of the metal deposition processes, various tool path patterns not only change the efficiency but also affect the deposition height, a critical quality for metal deposition process. This paper presents the research conducted on calculating zigzag pattern to improve efficiency by minimizing the idle path. The deposition height is highly dependent on the laser scanning speed. The paper also discussed the deposition offset pattern calculation to reduce the height variation by adjusting the tool-path to achieve a constant scanning speed. The results show the improvement on both efficiency and height.

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