Laser Assisted Micro Machining

Pratik S. Gandhi
B.Tech. Production
111213021
 Contents
1. Introduction
2. LAMM (Micro & Macro Scale)
3. LAMM on Ceramics
4. Setup & Parameters
5. Tool & w/p Contact Detection

6. Measured Responses
7. Laser Assisted Micro Grinding
8. Advantages & Disadvantages
9. Discussions & Conclusion
10. Area For Improvements
 Introduction

• Need – Parts with Micro Level Features

• Conventional Machining Process Imposes Limitations
• Micromachining – Range of Materials & Variety of Sizes
• Limitations – Low MRR, Tool Failure , Poor Feature
Accuracy
• Assistance – Cutting Fluids, Coating on Tools, Lubrications
 Introduction (Contd.)
• LAMM – Assist for Localized Thermal Softening
• Control – Power, Spot Size, Scan Speed
• Approaches :-
1. Thermal Softening of Hard Metals
2. Thermal Cracking of Ceramics
• Critical Distance between Tool & Laser Spot
 LAMM (Micro & Macro Scale)
Micro Scale
• Parameters – Wavelength,
Efficiency, Mode of Operation
a. Continuous Wave
b. Pulse Wave
• Common Lasers –
CO2, Nd- YAG, Excimer Laser
• Irradiation Mechanism for
Metal Removal
Macro Scale
• Reduction of Cutting Forces,
Rise in MRR
• Deformation Mechanisms &
Shear Zone Stresses
• Optimize Variables to
Minimize Tool Wear
• Excessive Heating –
Degradation of Microstructure
& Mechanical Properties
 LAMM on Ceramics
• Ceramics – High Temp. Wear Resistance, Chemical
Inertness, Good Strength-to-Weight Ratio
• Brittle Fracture – Surface Micro Cracks
• High Speed, Low Depth Multiple Cuts (Rough & Finishing)
• Continuous Wave Laser – Induce & Propagate Thermal
Cracks
• Local Tensile Stress – Crack Tip Development
• Rapid Laser Heating followed by Cooling
 Setup

• Ytterbium doped CW
Infra – red Fiber Laser
• Electric Motor – Spindle
Speed up to 80,000 rpm
• Machine – 3 Stacked
Linear Motion stages and
a Rotary stage
• Tool – Square End Mill,
TiAlN coated Tungsten
Carbide
 Setup (Contd.)

ATS – 125 AVS – 105 URS – 150cc

• X, Y • Rotary Motion
Translation
• Z Axis Lift • DC Servo
• 1 µm Motion Motor Driven
Accuracy
• 5 mm Travel • 360º Travel
• 100 mm
Travel • 50 N Max Range
Force • Speed - 80º/
• 180 N Axial
Force • Speed – 0.3 Sec
m/min • Max Force –
• Speed – 30 to 300 N
34 m/min
 Process Parameters

• Laser Power Desired Temp. Rise

• Wavelength – 1.06 m , Peak Power – 35 W
• Laser emission – 7 µm Dia Single Mode Fiber through a
Collimator
• Spot Size – Adjusting Distances between Lenses of
different Focal Lengths
• Positioning Error +/- 10 µm
 Tool & w/p Contact Detection

• Accurate Tool Setting => Dimensional Accuracy

1. Laser based Detection
2. Use of Machine Vision (High Magnification Camera
& Direct Line of Sight)
3. Electrical Signal Generation (Only for Conducting
Material)
4. Acoustic Emission Sensor – RMS Value of Output
Voltage
5. Spectral Content of Lateral Vibration of Milling
Spindle
 Measured Responses
• Resultant Force
a. R = Fx + Fy + Fz
b. 3 Axis Piezoelectric Dynamometer
c. Specific Cutting Energy – Average over each Groove
• Tool Wear
a. Change in Corner Radius of Tool Tip
b. LAMM => Less Rubbing & More Cutting at High Feed Rate
 Measured Responses (Contd.)
• Groove Geometry
In absence of Laser – Groove Profile varies due to Tool Wear

• Burr Height – Lager in LAMM due to Higher Ductility of

Softened w/p Material

• Heat Affected Zone – Tempered Region surrounds Laser

Path
 Laser Assisted Micro Grinding

• Laser Irradiation – Induce & Confine Thermal Cracks

• Cutting speed – 200 m/min
• Abrasive Grinding Pencil of Dia 0.8 mm
• Thin Layer of Material after Scanning by Laser becomes
Amorphous
• Constant Feed Rate
 Advantages & Disadvantages

Advantages Disadvantages

 Efficient Cutting of Hard  Higher Feed Rate; Not

Materials Proper Pre- Heat

 Excess Laser Power

 Short Manufacturing Time
lessen Material Hardness

 Economic Production of  High Temp at Tip causes

Complex Features Tool Wear

 Longer Tool Life due to  Feasible only up to Depth

Less Cutting Forces of cut of 3 mm
 Discussion & Conclusions

• LAMM results in reduction in Tool Wear & Cutting Stresses

• Resultant Forces decreased by nearly 60%
• Rounding of Tool Corner is Significantly lower
• Excessive Spot Size greater than Tool Dia increases Burr
Height
• Slow Scan by Laser makes the Material Soft; Results in
increase in Surface Roughness
• Though it is Efficient for Complex Features, it is useable
only for superficial cuts
 Area for Improvements

• Optimization of Laser Parameters – Use of Simulation

Softwares like ANSYS
• Tool Coatings & Cutting Edge Radius
• Setup can be used for Heat treatment process like Laser
Hardening
• Minimize Residual Thermally affected Zone
• Accuracy of Groove depends on Tool feed, Temp of Zone and
Strength of Tool
• Implementation on Commercial scale