Laser-Assisted Machining of Reaction Sintered Mullite Ceramics

Author:

Rebro Patrick A.1,Shin Yung C.1,Incropera Frank P.2

Affiliation:

1. School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907

2. College of Engineering, University of Notre Dame, South Bend, IN

Abstract

The present study focuses on the evaluation of the laser-assisted machining (LAM) of pressureless sintered mullite ceramics. Due to mullite’s low thermal diffusivity and tensile strength, a new method for applying laser power is devised to eliminate cracking and fracture of the workpiece during laser heating. The LAM process is characterized in terms of cutting force, surface temperature, chip morphology, tool wear, surface roughness and subsurface damage for a variety of operating conditions. Estimated material removal temperatures and the ratio of the feed force to the main cutting force are used to determine material removal mechanisms and regimes for brittle fracture and semi-continuous and continuous chip formation. Surface roughness and subsurface damage are compared between typical parts produced by LAM and grinding. Tool wear characteristics are investigated for variations in laser power, and hence material removal temperature, during LAM of mullite with carbide tools.

Publisher

ASME International

Subject

Industrial and Manufacturing Engineering,Computer Science Applications,Mechanical Engineering,Control and Systems Engineering

Reference18 articles.

1. Stinton, D. P., 1988, “Assessment of the State-of-the-Art in Machining and Surface Preparation of Ceramics,” Oak Ridge National Laboratory, ORNL/TM-10791.

2. Ko¨nig, W., and Wageman, A., 1991, “Fine Machining of Advanced Ceramics,” Proceedings of the 7th International Meeting on Modern Ceramics Technologies, Montecatini, Italy, Vol. D, pp. 2769–2783.

3. Ko¨nig, W., and Zaboklicki, A. K., 1993, “Laser-Assisted Hot Machining of Ceramics and Composite Materials,” International Conference on Machining of Advanced Materials, Gaithersburg, Maryland, NIST Special Publication 847, pp. 455–463.

4. Rozzi, J. C., Pfefferkorn, F. E., Shin, Y. C., and Incropera, F. P., 2000, “Experimental Evaluation of the Laser Assisted Machining of Silicon Nitride Ceramics,” ASME J. Manuf. Sci. Eng., 122, pp. 666–670.

5. Lei, S., Shin, Y. C., and Incropera, F. P., 2001, “Experimental Investigation of Thermo-Mechanical Characteristics in Laser-Assisted Machining of Silicon Nitride Ceramics,” ASME J. Manuf. Sci. Eng., 123(4), pp. 639–646.

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