Optimization of tungsten carbide processing parameters for laser heating and ultrasonic vibration composite assisted cutting

Abstract

Laser heating assisted cutting is a lucrative technique for machining difficult-to-machine materials such as tungsten carbide (YG20), which uses a high power laser to focally heat a workpiece before the material removal with traditional or innovative cutting tool. In the latter case, the application of ultrasonic vibration to the cutting edge was found to replace the continuous cutting mode to the interrupted one, it reduces the adhesion and entanglement of chips, improves the tool wear and surface roughness of the workpiece. The combination of laser heating assisted cutting and two-dimensional ultrasonic vibration cutting methods has been successfully applied by the authors of this paper for cutting of tungsten carbide (YG20). In this follow-up study, the proposed composite method is experimentally and theoretically verified. Through the mathematical model and simulation analysis, its advantages, including small cutting force, softening the effect and improved machining properties of the processed material (YG20) are corroborated. The dependencies between the laser power, cutting speed, depth of cut, and feed rate on the surface roughness are established via the response surface methodology. The genetic algorithm is applied to the optimization of machining parameters by setting the material removal rate as the object variable and surface roughness as a constraint variable. The results obtained strongly suggest that the optimized parameters improve the processing efficiency and furnish the required processing quality.

Keywords

Two-dimensional ultrasonic vibration cutting laser heating assisted cutting tungsten carbide optimization cutting parameters genetic algorithm

Get full access to this article

View all access options for this article.

References

Tamaki

Kubo

Sharif Ullah

AMM

. Wear characteristics of nano-polycrystalline diamond tool in cutting of tungsten carbide. Int J Mechatron Manuf Syst 2014; 7: 227–245.

Razak

Chen

Pasang

. Progression of tool deterioration and related cutting force during milling of 718Plus superalloy using cemented tungsten carbide tools. Int J Adv Manuf Technol 2016; 86: 3203–3216.

Okada

Yoshida

Furumoto

et al.

Mechanisms and characteristics of direct cutting of tungsten carbide using a diamond-coated carbide end mill. Int J Adv Manuf Technol 2016; 86: 1827–1839.

Liu

. Ductile cutting of tungsten carbide. J Mater Processing Technol 2001; 113: 348–354.

Zhang

Suzuki

Wang

et al.

Fundamental investigation of ultra-precision ductile machining of tungsten carbide by applying elliptical vibration cutting with single crystal diamond. J Mater Process Technol 2014; 214: 2644–2649.

Nath

Rahman

Neo

. Machinability study of tungsten carbide using PCD tools under ultrasonic elliptical vibration cutting. Int J Mach Tools Manuf 2009; 49: 1089–1095.

Nath

Rahman

Neo

. A study on the effect of tool nose radius in ultrasonic elliptical vibration cutting of tungsten carbide. J Mater Process Technol 2009; 209: 5830–5836.

Jiao

Niu

Liu

. Effect of ultrasonic vibration on surface white layer in ultrasonic aided turning of hardened GCr15 bearing steel. Mater Res Innov 2015; 19: 938–942.

Lin

Zhou

. Tool path generation for fabricating optical freeform surfaces by non-resonant three-dimensional elliptical vibration cutting. Proc IMechE, Part C: J Mechanical Engineering Science 2014; 228: 1208–1222.

10.

Paul

Sunil

Varadarajan

. The effect of cutting parameters on tool vibration during magnetorheological fluid controlled turning bar. Int J Acoust Vib 2017; 22: 27–33.

11.

Zhou

. Development of an innovative device for ultrasonic elliptical vibration cutting. Ultrasonics 2015; 60: 76–81.

12.

Jiao F, Niu Y, Zhang MJ, et al. Research on characteristics of tool wear in laser heating and ultrasonic vibration cutting of tungsten carbide. Adv Mech Eng 2016; 8: 1–9.

13.

Chen

Deng

et al.

Research on laser and mechanical compound truing and dressing of superabrasive grinding wheels. Zhongguo Jiguang/Chinese J Lasers 2012; 39: 0703002.

14.

Rahman Rashid

Sun

Wang

et al.

An investigation of cutting forces and cutting temperatures during laser-assisted machining of the Ti-6Cr-5Mo-5V-4Al beta titanium alloy. Int J Mach Tools Manuf 2012; 63: 58–69.

15.

Jiao

Niu

Zhang

. Prediction of machining dimension in laser heating and ultrasonic vibration composite assisted cutting of tungsten carbide. J Adv Manuf Syst 2018; 17: 35–45.

16.

Ahn

Woo

Lee

. A study on the energy efficiency of specific cutting energy in laser-assisted machining. Appl Therm Eng 2016; 94: 748–753.

17.

Mohammadi

Patten

. Effect of thermal softening on anisotropy and ductile mode cutting of sapphire using micro-laser assisted machining. J Micro and Nano-Manuf 2017. DOI: 10.1115/1.4035397.

18.

Ito

Kizaki

Shinomoto

et al.

High-efficiency and precision cutting of glass by selective laser-assisted milling. Precis Eng 2017; 47: 498–507.

19.

Kim

Lee

. A study on the laser-assisted ball-end milling of difficult-to-cut materials using a new back-and-forth preheating method. Int J Adv Manuf Technol 2016; 85: 1825–1834.

20.

Al-Ahmari

Ashfaq

Alfaify

et al.

Predicting surface quality of -TiAl produced by additive manufacturing process using response surface method. J Mech Sci Technol 2016; 30: 345–352.

21.

Ribeiro Filho

SLM

Lauro

Bueno

AHS

et al.

Influence cutting parameters on the surface quality and corrosion behavior of Ti-6Al-4V alloy in synthetic body environment (SBF) using Response Surface Method. Measurement 2016; 88: 223–237.

22.

Hao

. Prediction of laser cutting quality based on an improved Pareto genetic algorithm. Lasers Eng 2014; 27: 43–56.

23.

Solimanpur

Ranjdoostfard

. Optimisation of cutting parameters using a multi-objective genetic algorithm. Int J Prod Res 2009; 47: 6019–6036.

24.

Qin

et al.

Investigation of chip formation and fracture toughness in orthogonal cutting of UD-CFRP. Int J Adv Manuf Technol 2016; 82: 1079–1088.

25.

Liao

Axinte

. On chip formation mechanism in orthogonal cutting of bone. Int J Mach Tools Manuf 2016; 102: 41–55.

26.

et al.

Optimizacija konstrukcije rezne glave stroja za buenje primjenom ortogonalnog eksperimenta i analize konanih elemenata. Tehnicki Vjesnik 2016; 23: 707–714.

27.

Chen

. Optimized design and orthogonal experiment for processing microchannels with a CO2 laser beam. Lasers Eng 2017; 37: 197–206.

28.

Malakizadi

Cedergren

Sadik

et al.

Inverse identification of flow stress in metal cutting process using Response Surface Methodology. Simul Model Pract Theory 2016; 60: 40–53.

29.

Onwubolu

Mutingi

. A genetic algorithm approach for the cutting stock problem. J Intell Manuf 2003; 14: 209–218.

30.

Chen

et al.

Experimental study and genetic algorithm-based optimization of cutting parameters in cutting engineering ceramics. Int J Adv Manuf Technol 2014; 74: 807–817.