Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II IMECS 2009, March 18 - 20, 2009,

Hong Kong

Cutting Temperature and Laser Beam Temperature Effects on Cutting Tool Deformation in Laser-assisted Machining
J. W. Jung, C. M. Lee
manufacturing, etc. [4]. Materials processed by laser beam machining, range from metals and alloys to inorganic as well as organic non-metals, composites and rocks, etc. [5]. Pulsed Nd:YAG laser beam can be effectively used for cutting of silicon nitride ceramics and proper selection and controlling of laser beam machining process parameters can generate good quality cut surface during cutting of engineering ceramics [6]. Nd:YAG laser machining system can be continuously operated from a few watts to several hundred watts, but in most applications pulsed operation is preferred. Taper formation is the most important characteristics during laser micro-hole percussion drilling operation due to the inherent focusing characteristics of the laser machining process [7]. This paper presents the deformation errors caused by thermal effects in the laser-assisted machine tool. Laserassisted machine tool performs the localized heating and cutting process simultaneously. So, the heats generated by localized heating process as well as the cutting process are conducted into cutting tool. In order to predict deformation errors, the heats from the two heat sources have to be analyzed simultaneously and thermal distortion have to be calculated. The objective of this paper is prediction of thermal distortion by laser power and cutting temperature. Sequence of this paper consists of three steps. First step, the commercial software Simdesigner was used to analyze temperature distribution of material removal plane by moving heat source. Second step, after defining result of the analysis first step, commercial software AdvantEdge was used to calculate the cutting temperature by modeling as simple orthogonal cutting. Third step, the commercial software Simdesigner was used to analyze thermal distortion by inputting the calculated cutting temperature and force by the second step. The results can be used to increase the cutting accuracy by compensating thermal distortion prior to laser-assisted machining.
Abstract Laser-assisted machining uses primarily laser power to heat the local area before the material is removed. It not only efficiently reduces the cutting force during the manufacturing process but also improves the machining characteristics and accuracy with regard to difficult-tomachine materials. The prediction of relative deformations between the cutting tool and workpiece is important to improve the accuracy of machined components. This paper presents the deformation errors caused by thermal effects in the laser-assisted machine tool using finite element method. Key word Laser-assisted machining (LAM), Deformation, Accuracy, Finite element method (FEM)

I. INTRODUCTION Laser-assisted processing is one of the emerging fields in advanced manufacturing. The advantages that make the lasers increasingly attractive in industrial production include coherence, focusability, attractive, very high power intensity, power shaping capability and ease of automation with in-process sensing [1]. It also offers the potential to realize innovative design with high flexibility, a high processing speed, and good quality in many manufacturing processes. The capital investment may be higher, but this is offset by the benefits gained in many applications.[2] Increasing demand for advanced difficult-to-process materials and the availability of high-power lasers have stimulated interest in research and development related to laser machining.[3] Increasing interest in the use of lasers for manufacturing can be attributed to several unique advantages, which are generally applicable to the entire range of materials processing applications, such as high productivity, noncontact processing, elimination of finishing operations, adaptability to automation, reduced processing cost, improved product quality, greater material utilisation, minimal heat-affected zone (HAZ) and green
Manuscript received December 15, 2008. This work was supported by grant No. RTI04-01-03 from the regional Technology Innovation Program of the Ministry of Commerce, Industry and Energy(MOCIE) and AMECO Co.. J. W. Jung is with a Graduate student of the Mechanical Design and Manufacturing Engineering Department, Changwon National University, #9 Sarim-Dong, Changwon, Gyeongnam, Republic of Korea (e-mail: [email protected]). C. M. Lee is with the Mechanical Design and Manufacturing Engineering Department, Changwon National University, #9 Sarim-Dong, Changwon, Gyeongnam, Republic of Korea (corresponding author to provide phone: +82-55-279-7572; fax: +82-55-563-5221; e-mail: [email protected] .ac.kr ).

II. LASER-ASSISTED MACHINING A. Laser-assisted machining modeling Fig. 1 shows schematic for laser-assisted machining of a workpiece. The angle difference between the laser heating and the material removal plane is 180, as shown in Fig. 1. Type of laser beam is a CO2 laser and Gaussian beam. However, this paper ignores Gaussian beam in the finite element method. Table 1 presents specifications of the laser beam. The laser beam is used to heat workpiece before the material is removed.

ISBN: 978-988-17012-7-5

IMECS 2009

Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II IMECS 2009, March 18 - 20, 2009, Hong Kong

are used to obtain the cutting temperature and force during cutting by using AdvantEdge. 3. The results of the analysis step 2 are used to obtain the deformation of cutting tool using Simdesigner.

III. FINITE ELEMENT MODELING A. Finite element modeling of the analysis step 1 For the case of the analysis step 1, in order to obtain temperature distribution of material removal plane, it is needed to define finite element model. Mesh information of the analysis step 1 is shown in Table 2 and Fig. 3. Dimension of a cylindrical workpiece is 1630mm, the rotation speed is 440rpm and heat transfer coefficient of air is 11.2W/. Fig. 1 Laser-assisted machining of a cylindrical workpiece Table 1 Laser specifications Type CO2 Shape Cycle Profile diameter 3mm Power 319W B. Analyses steps The Fig. 2 shows three analyses steps for the deformation of cutting tool in laser-assisted machining. The three analyses steps are similarly composed of the real laserassisted machining, i. d., after heating the workpiece by moving laser beam, cutting analysis step is performed for the material removal. Table 2 Mesh information of a cylindrical workpiece Hexahedron (Parabolic/20node) Mesh type 10.33 17,460 75,384

Mesh size[mm] Elements number Node number

Fig. 3 Mesh of a cylindrical workpiece The rotation speed 440rev/min amount to 3mm/0.0081387s in order to model moving heat source of laser beam. Time step used for the analysis step 2 is 0.00406938s, which is half of 0.0081387s and total time is 0.0732483s for transient analysis. Table 3 Material properties of a cylindrical workpiece( Youngs modulus [GPa] Poissons ratio Density [kg/m3] Fig. 2 Three analyses steps for the deformation prediction of cutting tool 1. In order to obtain temperature distribution of arbitrary using Simdesigner, it is needed to define location boundary condition and input variables for moving heat source. 2. The results of the analysis step 1 and cutting conditions Moving heat source conditions for the transient analysis, nine heat areas are heated by moving heat source of 319W, the heating time and rate is shown in Fig. 4. The material properties for the workpiece are shown in Table 3 Thermal conductivity [W/m-] Specific heat [kJ/kg-] ) 300 0.3 3,200 16.9 0.72

ISBN: 978-988-17012-7-5

IMECS 2009

Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II IMECS 2009, March 18 - 20, 2009, Hong Kong

[8].

Fig. 5 shows rake, relief angle and geometry of a cutting tool. Cutting conditions are shown in Table 4. Mesh information of the analysis step 2 is shown in Table 5. Table 5 Mesh information of the analysis step 2 Maximum element size[mm] 0.1 Minimum element size[mm] 0.02 Max. number of nodes 12,000 Mesh type Triangle(CST) C. Finite element modeling of the analysis step 3 Fig. 6 shows 3D model of the cutting tool and generated mesh using automation mesh(tetrahedron) of CATIA V5 due to complicated geometry of the holder. The mesh information of the cutting tool is shown in Table 6 and material of the cutting tool is shown in Table 7[9].

Fig. 4 A transient analysis conditions B. Finite element modeling of the analysis step 2

Fig. 6 3D model and mesh of the cutting tool Table 6 Mesh information of the cutting tool Tetrahedron (Parabolic/10node) Mesh type Mesh size[mm] Elements Number Node Number (Insert)1 / (holder)4 12,629 20,333

(a)

(b) Fig. 5 Rake, relief angle and geometry of a cutting tool Table 4 Cutting conditions
Turning workpiece size Standard oblique tool modeler Turning the analysis step parameters Height[mm] 8 Edge radius[r] 0.02 Feed [mm/t ooth] 0.013 Side rake angle[a] -6 Length [mm] 5 Back rake angle[c] 0 Cutting speed [m/min] 21.7 Relief angle[b] 6 Initial degree [ ]
The results of step 2

Table 7 Material properties of the cutting tool SAE4140 CBN [holder] [insert] Youngs modulus [GPa] 205 680 Poissons ratio 0.29 0.22 Density [kg/m3] 7,861.1 3,120 Thermal conductivity 33 100 [W/m-] Specific heat [kJ/kg-] 0.56 0.7

Depth of cut [mm] 0.89

Length of cut[mm] 3

The result of temperature in analysis step 3 is obtained using thermal workbench in Simdesigner. Next, after defining the result of thermal workbench, the deformations of the cutting tool are obtained using static workbench in Simdesigner.

IV. ANALYSIS RESULTS A. Result of the analysis step 1 Fig. 7 shows temperature distribution by the analysis step 1.

2D analysis of AdvantEdge is carried out in the analysis step 2. A geometry and material data of a tool insert are obtained from tool manufacturer.

ISBN: 978-988-17012-7-5

IMECS 2009

Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II IMECS 2009, March 18 - 20, 2009, Hong Kong

The maximum temperature of moving heat source is 1826.9. The temperature distribution of some regions higher than other regions through the moving heat source line is supposed to be occurred due to discontinuous moving heat source and mesh size. Fig. 8 show temperature variations of 180, 90, 45 planes from the laser heating. Table 8 Mean temperature at material removal planes Location from the laser heating Mean temperature[] Fig. 7 Temperature distribution by the analysis step 1 Table 8 shows mean temperature at material removal planes in the path of moving heating source for analysis step 2. The mean temperature of 180 plane from the laser heating is the lowest as 197.4 because the material removal plane is far from laser heating. The mean temperature of 90 plane is 397.8 and 45 plane is 960.9. The closer location from the laser heating is defined, the higher mean temperature is occurred. The analyzed mean temperature is used as initial temperature of analysis step 2. (a) 180 plane from the laser heating B. Result of the analysis step 2 180 197.4 90 397.8 45 960.9

(b) 90 plane from the laser heating

Fig. 9 A cutting simulation Fig. 9 shows a cutting simulation of the analysis step 3. The simulation is performed to obtain peak temperature and cutting force. Fig. 10 show peak temperature() and x, y-direction force(N) of the cutting tool by AdvantEdge. The peak temperature analyzed by mean temperature 197.4 is 240.3, 421.1 by 397.8 and 961.1 by 960.9. The (c) 45 plane from the laser heating Fig. 8 Temperature variations of 180, 90, 45planes from the laser heating cutting force analyzed by mean temperature 197.4 is 18.2~20.0N, 17.6~19.3N by 397.8 and 0.2~0.3N by 960.9.

ISBN: 978-988-17012-7-5

IMECS 2009

Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II IMECS 2009, March 18 - 20, 2009, Hong Kong

(a) Result by mean temperature 197.4

(a) 180 plane from the laser heating

(b) Result by mean temperature 397.8

(b) 90 plane from the laser heating

(c) Result by mean temperature 960.9 Fig. 10 Peak temperature variations and forces by analysis step 2 The peak temperature is increased from the mean temperature due to cutting thermal effects during cutting. And the higher mean temperature is defined, the lower cutting force is occurred because the workpiece is softened by laser heating. The peak temperature and cutting force of analysis step 2 are used as input variables of the analysis step 3. C. Result of the analysis step 3 Fig. 11 show deformations of the cutting tool by the cutting temperature and force at 180, 90, 45 planes from the laser heating. Maximum deformations are 0.16mm at the 180 plane from the laser heating, 0.287mm at the 90 plane and 0.675mm at the 45 plane. The closer location from the laser heating is defined, the higher deformation error is occurred. Thus, the location from the laser heating is important for deformation errors of the cutting tool in laser-assisted machining.

(c) 45 plane from the laser heating Fig. 11 Deformations of the cutting tool

V. CONCLUSION The prediction of relative deformations between the cutting tool and workpiece is important to improve the accuracy of machined components using finite element method (FEM). This paper presents prediction of thermal distortion by laser power and cutting temperature. Sequence of this paper consists of three steps. First step, the commercial software Simdesigner was used to analyze temperature distribution of material removal plane by moving heat source. Second step, after defining result of the analysis first step, commercial software AdvantEdge was used to calculate the cutting temperature by modeling as simple orthogonal cutting. Third step, the commercial software Simdesigner was used to analyze thermal distortion by inputting the calculated cutting temperature and force by the second step. 1. The peak temperature is increased from the mean temperature due to cutting thermal effects during cutting. And the higher mean temperature is defined, the lower cutting force is occurred because the workpiece is softened by laser heating. 2. The closer location from the laser heating is defined, the higher deformation errors are occurred. Thus, the

ISBN: 978-988-17012-7-5

IMECS 2009

Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II IMECS 2009, March 18 - 20, 2009, Hong Kong

location from the laser heating is important for deformation errors of the cutting tool in laser-assisted machining. 3. The results can be used to increase the cutting accuracy by compensating thermal distortion prior to laserassisted machining.

ACKNOWLEDGMENT This work was supported by grant No. RTI04-01-03 from the regional Technology Innovation Program of the Ministry of Commerce, Industry and Energy(MOCIE) and AMECO Co..

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ISBN: 978-988-17012-7-5

IMECS 2009