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Journal of Manufacturing Processes: Jong-Tae Baek, Wan-Sik Woo, Choon-Man Lee
Journal of Manufacturing Processes: Jong-Tae Baek, Wan-Sik Woo, Choon-Man Lee
A R T I C LE I N FO A B S T R A C T
Keywords: Difficult-to-machine materials are being widely used in various industries. However, these materials are much
Induction assisted machining (IAM) more difficult to machine using conventional machining (CM) methods than other common materials, because of
Laser-induction assisted machining (LIAM) their superior material properties such as high strength, stiffness and brittleness. Thermally assisted machining
Cutting force (TAM) methods have been developed to address this problem. Laser assisted machining (LAM) is a type of TAM
process in which a workpiece is locally softened by a laser heat source in front of the cutting tool. The method is
an effective way to enhance machinability when processing various difficult-to-cut materials. Two other ap-
proaches, induction assisted machining (IAM) and laser-induction assisted machining (LIAM), were analyzed
and experimentally investigated in this study to compare their efficiency with that of CM for two materials, AISI
1045 steel and Inconel 718. It was found that cutting force was decreased and surface quality was improved
when the IAM and LIAM were used.
1. Introduction TAM and a new preheating method was proposed to improve the pre-
heating effect [9–11]. By using heat to soften the metal workpiece prior
Thermally assisted machining (TAM) is an economic, rapid-heating to machining, TAM can reduce the energy used for cutting materials by
heat treatment technique for enhancing the machinability of materials. reducing the amount of force which needs to be applied to the work-
TAM has been used extensively in industry for various applications over piece. Among the various TAM processes, the laser assisted machining
the past few decades, and has been widely investigated by researchers. (LAM) process locally softens a workpiece using a laser heat source.
TAM is mainly applied to difficult-to-cut materials which cause high Induction assisted machining (IAM) is also an effective TAM method.
machining cost by conventional machining (CM) methods. Shin et al. IAM is a non-contact process which requires no physical interaction
performed TAM of titanium alloy and nickel alloy. The cutting force with the metal material. An induction heat source can be used for
was reduced by about 20% compared with the CM, and the tool wear preheating, welding, heat treatment, melting, etc. [4,12,13]. Also, the
was also reduced. In addition, machining costs such as laser, tool, tool induction heat source can be replaced at a cost of about one tenth of the
exchange and operation costs were decreased by about 30–50% com- laser heat source, and the quality of induction heating can be superior
pared to CM [1,2]. They performed thermal and mechanical modeling to that of a laser heat source because the heating can be applied more
analysis for micro machining using TAM on three difficult-to-cut ma- evenly to the metal surface in various manufacturing methods [4]. In
terials. The reliability of the analysis model was verified by comparing this study, the use of multi-heat sources (laser-induction) is proposed
the simulation results with the experimental results [3]. Some re- for the first time in TAM. The laser produces a narrow and deep heat
searchers conducted the TAM using various heat sources to verify the affected zone (HAZ), and the induction produces a wide and shallow
effectiveness of the TAM. As a result, machining characteristics such as HAZ. Therefore, when using laser-induction, the disadvantages of a
cutting force, specific cutting energy, tool wear and surface roughness single heat source can be supplemented and the material removal rate
were enhanced by TAM [4–7]. Recently, Ito et al. has applied TAM to (MRR) can be improved as the HAZ increases. In addition, low output
precisely machine a glass. The surface roughness was reduced by 74%. lasers can be used by using the high output induction with low cost.
The tool life was shortened, but the glass was precisely machined by Therefore, it is possible to reduce initial costs by using the low cost laser
TAM [8]. Lee et al. successfully machined the specimens with the three- with low power, and it is possible to achieve equal or better machining
dimensional shape such as cylindrical and spherical shape using the efficiency as compared with the use of high power laser. The use of
⁎
Corresponding author.
E-mail address: cmlee@changwon.ac.kr (C.-M. Lee).
https://doi.org/10.1016/j.jmapro.2018.06.030
Received 30 May 2017; Received in revised form 15 June 2018; Accepted 19 June 2018
1526-6125/ © 2018 Published by Elsevier Ltd on behalf of The Society of Manufacturing Engineers.
J.-T. Baek et al. Journal of Manufacturing Processes 34 (2018) 513–522
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J.-T. Baek et al. Journal of Manufacturing Processes 34 (2018) 513–522
2. Thermal analysis
∂D ∇∙B = 0 (4)
∇×H=J+
∂t (1)
where H denotes the magnetic field intensity or B / μ , J is the conduction
∂B current density or σE , D is the electric displacement or εE , t is time, E is
∇×E= − the electric field intensity, B is the magnetic flux density and ρ is the
∂t (2)
charge density. Because of the non-linearity of the electromagnetic field
∇∙D = ρ (3) it is generally described by Eq. (4), based on the Maxwell equations.
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Fig. 2 shows a schematic diagram of the IAM process. The difficult-to- Figs. 3 and 4 show the thermal conductivity and specific heat with
machine materials are removed by cutting tool after softening by in- temperature change of AISI 1045 steel and Inconel 718 [11,29]. Fig. 5
duction preheating. shows the tensile strength of Inconel 718 [9,11]. For the thermal ana-
lysis, the preheating temperature should be selected considering the
2.1.1. Thermal analysis conditions mechanical strength according to the temperature of each material. The
Thermal analysis in this study was conducted for the induction mechanical strength of the material is greatly reduced above a certain
heating process of two materials, AISI 1045 steel and Inconel 718. As temperature. Therefore, after preheating temperature of each material
noted, since thermal conductivity and specific heat change non-linearly is selected, it is applied to analysis model to confirm temperature dis-
with material temperature, the thermal conductivity and specific heat tribution. The selected preheating temperature was set based on the
of the materials must be considered for accurate thermal analysis. maximum temperature of the material surface. In this study, heat
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Fig. 12. Experimental set-up and equipment for CM, IAM and LIAM.
Table 1 Table 2
Machining conditions for AISI 1045 steel. Machining conditions for Inconel 718.
Machining method Feed rate Spindle Depth of Material Machining method Feed rate Spindle Depth of Material
[mm/ rotation speed cut [mm] removal rate [mm/ rotation speed cut [mm] removal rate
min] [rpm] [MRR] min] [rpm] (MRR)
[mm3/min] [mm^3/min]
Induction assisted 120 3000 0.2 192 Induction assisted 120 3000 0.1 96
machining 4,000 0.7 672 machining 5000 0.3 288
5000 1.2 1152 7000 0.5 480
Preheating temperature of induction assisted milling: 700 ℃. Preheating temperature of induction assisted machining: 900 ℃.
Preheating temperature of laser-induction assisted milling: 700 ℃. Preheating temperature of laser-induction assisted machining: 900 ℃.
MRR (material removal rate, the volume of material removed per
minute) = Depth of cut (D)*Width of cut (W)*Feed rate (F) = mm3/min. used as user custom methods. First, the mesh of the all surfaces was
divided by 1 mm. Second, to increase the quality of the mesh, a mapped
generated to material during machining was not considered because the mesh was used on all surfaces. The diameter of induction coil is 8 mm.
heat generated during the machining is mainly transferred to the chip
and less than 10% of the generated heat is transferred to the workpiece. 2.1.2. Analysis results for AISI 1045 steel
In addition, the TAM preheated to a high temperature is not sig- The annealing temperature and A1 transformation temperature of
nificantly affected by the heat transferred to the material during ma- AISI 1045 steel are known to be 550 and 726 ℃, respectively. Thus,
chining. residual stress in the AISI 1045 steel can be removed by machining in
Fig. 6 shows the generated mesh shape. The mesh element is divided the range of 550–726 ℃. The above conditions are important because it
by 0.5 mm and the mesh around the moving heat source is locally di- is necessary to avoid phase transformation of the material during pre-
vided by 0.5 mm in order to increase the accuracy of the analysis. The heating and machining [7,9,11].
finite element discretization was performed by the hexagon dominant To prevent phase transformation, the preheating temperature of the
mesh (Quad/Tri) and user custom methods, the number of nodes was AISI 1045 steel was established to be between the annealing tempera-
441,601 and the number of elements was 105,000. Two methods were ture (550 ℃) and the A1 transformation temperature (726 ℃). The
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Table 3 material surface was monitored in real time. The cutting force was
Maximum size of tool wear and surface roughness of AISI 1045 steel. measured by Kistler’s 9527B dynamometer. A carbide cutting tool
Conventional Induction Laser-induction (WIDIN ZE324061) with diameter of 8 mm, length of 100 mm and 4
machining assisted assisted flutes was used during machining [7,9–11].
machining machining
3.2. Machining conditions
Tool wear (mm) 1.179 0.380 0.007
Surface roughness, 0.673 0.415 0.332
Ra (㎛) In CM, IAM and LIAM, the workpiece is kept in a fixed position and
the tool is rotated counterclockwise. The feed rate was chosen to be
120 mm/min because the speed of the laser module in the experimental
2.2.2. Analysis results for Inconel 718 set-up was limited to this rate. Depth of cuts of both materials are de-
Fig. 11 shows the temperature distribution in Inconel 718. The termined with consideration of the effective depth of cut. In order to
LIAM preheating temperature was determined to be 900 ℃. The effec- compare each machining method equally, it was chosen within the
tive depth of cut was determined to be approximately 0.7 mm con- effective depth of cut of the IAM. The machining conditions of the AISI
sidering the depth where the temperature up to 650 ℃, where the 1045 steel and Inconel 718, such as feed rate, spindle rotation speed,
tensile strength is decreased. As with the results in Section 2.1.1, the depth of cut and preheating temperature, are shown in Tables 1 and 2,
effective depth of cut in LIAM can be obtained a deeper depth of cut respectively.
than the IAM.
4. Results and discussion
3. Experiments
4.1. AISI 1045 steel
3.1. Experimental set-up
Fig. 13 shows the experimental results of the cutting forces of AISI
Fig. 12 shows the experimental set-up used to verify the perfor- 1045 steel based on the different machining methods. The cutting
mances of CM, IAM and LIAM. IAM device was built at about one tenth forces are decreased with the preheating temperature rise. These results
the cost of LAM device. The 5-axis machining center is the Hi-V560M by show IAM and LIAM are effective methods for decreasing cutting force.
Hyundai WIA. The laser module is a high-power diode laser with a The cutting forces were also decreased by increasing spindle rotation
maximum output of 1 kW. The induction module is a 6 kW high fre- speed, both with and without preheating. LIAM was determined to be
quency Induction Heater by Tae-yang Induction Heater Co., Ltd. It the most efficient method for reducing cutting force. When the depth of
provides a much better heating and faster ability than current existing cuts were 0.2 mm, 0.7 mm and 1.2 mm, at a spindle rotation speed of
induction heating processes. The laser temperature pyrometer is the 3000 rpm, the LIAM cutting forces decreased by about 91%, 47% and
LPC03 pyrometer by Dr. Mergenthaler GmbH & Co. KG. The tempera- 13%, respectively, as compared with CM. Also, in LIAM, the measured
ture measurement range is 400–3000 ℃. The IR temperature pyrometer cutting force was less than in the CM and IAM method in all cases.
process sensor was a PSC-CS-Laser-2MH Series. The temperature mea- Table 3 and Fig. 14 show the tool wear, the surface roughness and
surement range is 385–1600 ℃. The laser temperature pyrometer and the surface machined at 5000 rpm and a depth of cut of 1.2 mm. The
induction temperature pyrometer were attached to the 5-axis ma- cutting force is focused on the edge of the cutting tool. Softening the
chining center at the surface of the material, and the temperature of the materials by different heat sources significantly reduced friction and
Fig. 14. Tool wear, and the machined surface of AISI 1045 steel, for the different machining methods.
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5. Conclusions
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Fig. 16. Tool wear, and the machined surfaces of Inconel 718, produced by the different machining methods.
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