Thermal Field Modeling and Experimental Analysis in Laser-Assisted Machining of Fused Silica
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ORIGINAL PAPER
Thermal Field Modeling and Experimental Analysis in Laser-Assisted Machining of Fused Silica Pengfei Pan 1
&
Huawei Song 1 & Zuohui Yang 1 & Guoqi Ren 1 & Junfeng Xiao 1 & Xiao Chen 1 & Jianfeng Xu 1
Received: 25 February 2020 / Accepted: 24 August 2020 # Springer Nature B.V. 2020
Abstract Fused silica, a high-strength brittle material, is widely used in optical, aerospace, and laser industries. However, a high-efficiency and high-quality machining method for fused silica is widespread demand in the industry. In this paper, based on the threedimensional cylindrical transient heat transfer model and cutting experiments, the cutting performance of fused silica in laserassisted machining (LAM) is studied. The finite element method is adopted to simulate the temperature field in the LAM of fused silica, and the temperature distribution of the workpiece surface is obtained. The results show that the material softens sufficiently under high laser power, low feed rate, low rotational speed, and preheating process. The verification experiments were then performed based on the range of parameters selected from the thermal model analysis. The cutting performance with different parameter combinations was compared, such as cutting force, surface roughness, machined surface integrity, and chip morphology. The results show that the smaller surface roughness, the lower cutting force, the smoother surface topography, and the largesize semi-continuous chips are obtained under the optimal combination of parameters, further demonstrating that the thermal model can provide a practical guide to improve the machinability of fused silica. Keywords Laser-assisted machining . Fused silica . Thermal model . Cutting performance
1 Introduction Fused silica, an amorphous material composed of high-purity silica, has a specific performance in physicochemical, mechanical, and optical properties due to its amorphous structure [1]. Fused silica has a wide range of applications in optics, high power lasers, precision instruments, and aerospace, owing to its excellent corrosion resistance, low thermal conductivity and expansion coefficient, outstanding thermal shock resistance, and superior spectrum characteristic. However, the high brittleness, high hardness, and low fracture toughness of fused silica make it challenging to obtain excellent processing quality with high efficiency through conventional processing such as grinding and polishing. Moreover, severe tool
* Jianfeng Xu [email protected] 1
State Key Laboratory of Digital Manufacturing Equipment & Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
wear and low material removal rates result in high processing costs for fused silica, limiting its application [2]. Laser-assisted machining (LAM) has been considered as an alternative process for machining difficult-to-cut materials, such as engineering ceramics [3, 4], hardened steels [5], superalloy [6, 7], titanium alloy [8], particle-reinforced matr
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