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The Effect of a Laser Beam on Chip Formation during Machining of Ti6Al4V Alloy

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Abstract

The effect of the laser beam on chip formation when machining Ti6Al4V alloy has been investigated at different cutting speeds and laser powers. The characteristics of the segmented chip produced by laser-assisted machining (LAM) in terms of the tooth depth and tooth spacing were strongly dependent on the cutting speed and laser power. Two types of segmented chip formation processes were observed, one at low and the other at high cutting speeds with a continuous chip occurring between these two types of segmented chips. The critical cutting speed at which the transition from the sharp, segmented chip to the continuous chip occurred increased with laser power. To obtain the continuous chip, plastic deformation at the shear zone to match the deformation strain introduced by the cutting tool is required. This can be achieved by laser heating the material in front of the cutting tool. A physical model is proposed to explain qualitatively the chip segmentation in conventional machining and the continuous chip transition at high cutting speed with the application of a laser beam.

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  1. INCONEL is a trademark of Special Metals Corporation, New Hartford, NY.

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Acknowledgments

The authors gratefully acknowledge the CAST Cooperative Research Centre for supporting this work. The CAST Cooperative Research Centre was established and is supported under the Australian Government’s Cooperative Research Centres Programme. The authors would also like to acknowledge the support of the Defence Materials Technology Centre, Australia.

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Authors and Affiliations

  1. CAST CRC, the Industrial Laser Applications Laboratory, IRIS, Faculty of Engineering and Industrial Sciences, Swinburne University of Technology, Hawthorn, Victoria, 3122, Australia

    S. Sun (Research Engineer)

  2. CAST CRC, School of Aerospace, Mechanical and Manufacturing Engineering, RMIT University, Bundoora, Victoria, 3083, Australia

    M. Brandt (Professor)

  3. DMTC, CAST CRC, School of Mechanical and Mining Engineering, University of Queensland, Brisbane, Queensland, 4072, Australia

    M.S. Dargusch (Technology Manager)

Authors
  1. S. Sun
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  2. M. Brandt
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  3. M.S. Dargusch
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Correspondence to S. Sun.

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Manuscript submitted March 10, 2009.

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Sun, S., Brandt, M. & Dargusch, M. The Effect of a Laser Beam on Chip Formation during Machining of Ti6Al4V Alloy. Metall Mater Trans A 41, 1573–1581 (2010). https://doi.org/10.1007/s11661-010-0187-5

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