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 Macro Scale
• Parameters – Wavelength, • Reduction of Cutting Forces,
Efficiency, Mode of Operation Rise in MRR
a. Continuous Wave • Deformation Mechanisms &
b. Pulse Wave Shear Zone Stresses
• Common Lasers – • Optimize Variables to
CO2, Nd- YAG, Excimer Laser Minimize Tool Wear
• Irradiation Mechanism for • Excessive Heating –
Metal Removal 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
