Experimental Investigation of Milling Performance of Silicon Nitride Ceramic Subject to Different Assisted Systems

Abstract

In this study, silicon nitride milling experiments are carried out using Polycrystalline Diamond (PCD) end mill rods under unassisted, hybrid-assisted (combination of laser assisted and three axis ultrasound), and laser-assisted systems to examine the cutting performance and machined surface quality of different cutting tools. The best combination of process parameters for silicon nitride composites milling are obtained using the Taguchi method. The effects of spindle speed, radial depth of cut, and feed rate on surface roughness, cutting force, edge topography, and tool wear of silicon nitride surfaces are investigated. The results reveal that hybrid-assisted produces superior surface roughness, longer tool life, fewer machining defects, and lower cutting force than unassisted. Best results of triaxial ultrasonic-assisted combined with laser on cutting performance are achieved as the ultrasonic waves help to vibrate the cutting tool and workpiece simultaneously, which helps to effectively remove chips and lowers the cutting force. When compared to unassisted milling, laser-assisted and hybrid-assisted milling improve total average surface roughness by 42% and 66%, and total cutting forces by 26% and 46%, respectively. The best processing parameters obtained in this study are high spindle speed (12,000 rpm), low feed rate (500 mm/min), and low cutting depth (0.02 mm).