Manufacturing of 3-axis machine used for cutting

ceramic work piece.

Abstract: - Nickel-based super alloys including Inconel 718 (IN718) are widely used in aerospace
industries due to their superior high temperature strength, toughness, and corrosion resistance. These
alloys are difficult to machine mainly because of their low thermal conductivity and high work hardening
rate, which cause steep temperature gradient and high cutting forces at the tool edge. Super alloys have
high strengths at elevated temperatures, which make them attractive toward various applications and
also make these materials difficult to machine at room temperature due to excessive tool wear and poor
surface finish. Laser-assisted machining (LAM) offers the ability to machine super alloys more efficiently
and economically by providing the local heating of the work piece prior to material removal by a single
point cutting tool. The machinability of Inconel 718 under varying conditions is evaluated by examining
tool wear, forces, surface roughness, and specific cutting energy.
Keywords: Laser-assisted machining; Inconel 718; Super alloys; Ceramic.

Introduction
Laser assisted machining is one of the advanced manufacturing process. Laser assisted machining
improves machining characteristics by reducing the cutting force finishing the surface roughness and
tool wear. Now a days Ceramics and super alloys are mainly used in aerospace industries due to their
oxidation- and corrosion-resistant property. Inconel is used to make dome, aft shaft, whereas Ceramics
are used to make nose and outer dome in missiles. Machining of super alloys and ceramics is expensive.
In order to reduce machining cost laser assisted machining process is considered for machining. Laser
technology offers different method of beam generation with continuous wave or pulsed wave of m. In
laser beam power may vary from 109 W/cm2 to 1015 W/cm2. We have used Nd:YAG laser which act as a
heat source.

Methodology
This project is divided in three different part.
1. Turning of superalloy with a hard submicron substrate, TiAlN PVD coated grade followed by a
special 'SUMO TEC' surface treatment. Suitable for turning hard nickel base alloys / Inconel (4050 HRC) at low to medium cutting speeds.
Tool supplier ISCAR
Item Code: - CNMG 120408

Material: - Inconel 718.

Property of Inconel 718

Ni

Cr

Fe

Mo Nb Co Mn Cu

50.0 17.0 balance 2.8

55.0 21.0
3.3

4.75 1.0
5.5

0.35

Al

Ti Si

0.2 0.65 0.3 0.35 0.08 0.015 0.015 0.006

0.8 1.15

Cutting tool Geometry

Turning operation was performed on a high speed precision lathe by HMT model No. N22, having
maximum spindle speed of 2040rpm feed of .1mm is given per cycle and tool life is calculated after 10
cycles.
2. In second part of experiment laser is used in HMT model No. N22, laser head is used to project
laser perpendicular to the work piece, laser head is attached to this laser arm.
Laser specifications
Manufacturer: -

FANUC

Model No.:-

FANUC Laser C4000i

Laser type: -

Nd:YAG laser (pulsed)

Wavelength: -

1064 nm

Polarization of beam: -

Random

Beam average power, (W)

6, 7, 8, 9 and 10

Pulse frequency, Hz

3000, 4000, 5000, 6000, 7000

3. In this stage of we are planning to synchronize laser arm with CNC machine, CTX 410

V3 by GILDEMEISTER, with the help of stepper motor.

Laser Arm 3-D Model in Siemens Nx 8.5.

References

Analysis of tool wear patterns in finishing turning of Inconel 718.

Modeling of machining of composite materials
Investigation into the effect of overlap factors and process parameters on surface roughness
and machined depth during micro-turning process with Nd:YAG laser
Laser machining of structural ceramics.
Pulsed laser-assisted machining of Inconel superalloy.