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Thermal Modeling and

Experimental Investigation for


Laser Assisted Milling of Silicon
Nitride Ceramics
Xinwei Shen
This study is motivated by the fact that temperature control is very important for the
Shuting Lei success of laser assisted milling. A transient three-dimensional thermal model is devel-
oped using finite element analysis for laser assisted milling (LAMill) of silicon nitride
Department of Industrial and Manufacturing ceramics, and then validated through a series of experiments of laser assisted face mill-
Systems Engineering, ing. This study aims to explore the thermal characteristics in LAMill of silicon nitride
Kansas State University, ceramics and thus provide guidelines on parameter selection for future operations. In
Manhattan, KS 66506 addition, heat generation associated with machining is considered, and the effects of
laser power, feed, and cutting speed on temperature are investigated. Simulation results
show that heat generation associated with machining can be neglected. Laser power is
one critical parameter for successful operation of LAMill. Moreover, both feed and cut-
ting speed can affect the operating temperatures by varying feed rate; however, once feed
rate is fixed, they have a little impact on the operating temperatures.
关DOI: 10.1115/1.3184086兴

Keywords: laser assisted milling (LAMill), silicon nitride, thermal model, finite element
analysis (FEA), heat generation

1 Introduction radiation and convection. It should be noted that, in addition to


thermal radiation and convection, all the above-mentioned models
Laser assisted machining 共LAM兲 can potentially decrease ma-
neglected the temperature-dependent thermophysical properties of
chining cost, improve efficiency, and reduce surface/subsurface
the materials, especially thermal conductivity and specific heat.
flaws of ceramics. König and Zaboklicki 关1,2兴 demonstrated the
However, the following thermal models made much improve-
feasibility of LAM for advanced ceramics and pointed out that
ment in dealing with these issues. Both the temperature-dependent
LAM is one kind of hot machining. Shin et al. 关3兴 also indicated
that LAM is one kind of thermally assisted machining techniques thermophysical properties and the boundary conditions of thermal
and temperature is critical to the successful operation of LAM. convection and radiation were considered. Rozzi et al. 关9,10兴 used
Apparently, temperature analysis is necessary and very important FVM to develop a transient three-dimensional thermal model for
in LAM. Currently, the effective approach to achieve it is through laser assisted turning of silicon nitride. They pointed out that laser
numerical modeling. translational speed, laser power, cutting speed, and laser beam will
The modeling methods involve analytical treatment, finite dif- affect the workpiece surface temperatures. Rebro et al. 关11兴 ex-
ference method 共FDM兲, finite volume method 共FVM兲, and finite tended the model to mullite ceramics. Through evaluating the
element analysis 共FEA兲. Westkämper 关4兴 developed a two- axial and radial thermal gradients, they presented a two-step
dimensional FEA model for laser assisted grinding of silicon ni- power method for applying laser power thus avoiding thermal
tride, but detailed description of the model was not given. Janvrin fracture and crack formation. Also, Pfefferkorn et al. 关12兴 ex-
关5兴 built a three-dimensional heat conduction model for laser as- tended the model by Rozzi et al. 关9兴 to partially stabilized zirconia
sisted turning of silicon nitride using FDM. In this model, a con- 共PSZ兲 ceramics. Internal radiation, diffusion, and convection are
stant temperature at the laser-beam covered region was assumed. specially considered because of semitransparent zirconia 共PSZ兲
Thermal radiation and convection were neglected and the material ceramics. They found that laser power, feed, and depth of cut have
removal was not considered. Gutierrez and Araya 关6兴 established considerable impact on the temperature distribution. Tian and
an analytical conduction model for laser assisted machining of Shin 关13兴 improved the model by Rozzi et al. 关9兴 to the complex
silicon nitride. They also neglected thermal radiation, convection, feature. They concluded that laser power has the most significant
and the material removal. In order to find the temperature distri- influence on the workpiece temperature, then feed and lastly
bution for laser assisted planing of Al2O3 ceramics, Chang and spindle speed. Also, Singh et al. 关14兴 developed a three-
Kuo 关7兴 developed a two-dimensional transient heat conduction dimensional transient FEA model for laser assisted microgrooving
model and applied lattice Boltzmann method 共LBM兲 to calculate of a mold steel and successfully predicted the temperature distri-
the temperatures inside the ceramic workpiece. They did not con- butions of the heat-affected zone 共HAZ兲 in the workpiece.
sider thermal radiation and convection. A quasi-steady-state ana- All literature mentioned above is focused on laser assisted turn-
lytical thermal model was established by Ching et al. 关8兴 for laser ing, grinding, planning, and microgrooving. As for laser assisted
assisted turning of zirconia ceramics. Similarly, they did not con- milling 共LAMill兲, König et al. 关15兴 first showed its feasibility of
sider the material removal and boundary conditions of thermal cutting “difficult to machine” materials such as stellite 6. Jeon and
Pfefferkorn 关16兴 successfully conducted laser assisted micro-end-
milling to improve the chip load and productivity in metal cutting.
Contributed by the Manufacturing Engineering Division of ASME for publication
in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received
For ceramic materials, Shen and Lei 关17兴 initially did some nu-
October 30, 2008; final manuscript received June 24, 2009; published online merical simulations for laser assisted face milling of silicon ni-
September 8, 2009. Review conducted by Suhas Joshi. tride, which were conducted through a transient three-dimensional

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Fig. 1 Schematic of laser assisted face milling

heat transfer model using FEA. With this model, a parametric and cutting speed. Hence, through thermal analysis, guidelines for
study was conducted involving parameters of laser power, laser- the parameter selection can be made and thus the thermal gradi-
beam diameter, laser moving speed, and preheat time. After this, ents over the cutting zone can be reduced. So far no literature has
Shen et al. 关18兴 improved that model 关17兴 so that it could be used reported on the thermal analysis of the cutting zone in detail for
to predict the potential surface/subsurface cracks through thermal LAMill. In addition, previous researchers usually neglected heat
stress analysis. However, neither the material removal nor model generation associated with machining in their thermal models, be-
validation was performed for both models. Later on, Yang et al. cause they argued that the value was very small compared with
关19兴 conducted a number of experiments of laser assisted face the energy from the laser source, while this study conducts simu-
milling, but no thermal model was built for this operation. They lations to explore its effect on the temperature at the cutting zone.
indicated that as operating temperature increases, both the cutting In the following, the FEA model is first introduced in detail in
force and specific cutting energy decrease. Yang and Lei 关20兴 Sec. 2 and an example of temperature distribution is illustrated in
further pointed out that once the operating temperature is higher Sec. 4. Then, model validation is conducted in Sec. 5 via varying
than 1000° C, entry edge chipping was not observed. Exit edge the parameters of laser power, feed, and cutting speed. Finally, in
chipping decreases considerably as the temperature increases. Sec. 6, some guidelines on parameter selection is provided for
Tian et al. 关21,22兴 also did some experiments of laser assisted future laser assisted milling operations.
milling of silicon nitride. The TiAlN coated carbide end mills
were used. They indicated that there was a narrow range of ma-
terial removal temperature 共about 1200– 1300° C兲 with the TiAlN 2 Transient Three-Dimensional FEA Model
coated carbide tools. Also, a transient three-dimensional thermal
model was developed using FVM. However, the model only fo- 2.1 Mathematical Description of the Model. Figure 1 illus-
cused on laser heating without considering the material removal, trates the schematic of laser assisted face milling of silicon nitride
and only the effect of laser power was discussed. ceramics in this study. The laser is positioned in front of the mill-
This study improves our previous FEA thermal model 关18兴 by ing cutter. Between the laser spot and the cutter, a small distance,
considering material removal, and the new model is validated laser-cutter allowance, is maintained in case the laser spot over-
through a series of experiments of laser assisted face milling of laps and damages the cutter. The workpiece is fed into the milling
silicon nitride ceramics. Temperature simulation reveals that ther- cutter along the z direction, which is clamped by an insulated vise
mal gradients exist inside the workpiece in LAMill due to local- so as to prevent the heat dissipation from the workpiece. The
ized laser heating. Basically, for a successful LAMill, small ther- clamped areas 共S1兲 are shown in gray in Fig. 1. The remaining
mal gradients in the workpiece are expected, especially over the areas on the workpiece surfaces are exposed to the surroundings.
cutting zone. They are strongly affected by the parameters of The heat transfer model can be described by the following gov-
LAMill such as laser power, laser-beam diameter, feed rate, feed, erning equation integrating over the volume of the workpiece:

共1兲

where S2 is the area covered by the laser beam 共laser spot兲, S3 is In Eq. 共1兲, the first, second, and third terms on the left-hand side
the area where the cutter is in contact with the workpiece in one represent the change in the internal energy, energy convection,
cut, and S4 are the areas including all the workpiece surfaces open and radiation, respectively. The first term on the right-hand side
to the surroundings except S2 and S3. represents input heat flux from the laser source. The second term

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Fig. 3 Schematic of cutting zone in face milling
Fig. 2 FEA model with one-half of the workpiece

Around the target machining portion, fine uniform meshes with


brick shape are generated with the dimensions of 0.12x ⫻ 0.12z
shows the energy from the heat generation due to plastic defor- ⫻ 0.1y mm3, and beyond this portion, nonuniform meshes are
mation and tool-workpiece friction, which is associated with ma- used. The model has a total of 17x ⫻ 236z ⫻ 34y elements and
chining. The last term represents the energy conduction across the 149,310 nodes.
workpiece surfaces. Actually, for the whole volume of the work- Still, some other features of the model are specified in the fol-
piece, the final integration result of the last term is equal to zero lowing.
because nothing contacts the workpiece except the insulating ma-
terials, which is considered to be adiabatic. However, for an ele- 共1兲 In this study, allowing for the existence of thermal gradi-
ment 共or very small volume兲 inside the workpiece, the final inte- ents in the workpiece, the minimum temperature over the
gration result of the term is not zero. cutting zone is used as the operating temperature for mate-
The initial condition of the thermal model is rial removal rather than the average one that some other
work used 关9,11,12,21,22兴. The purpose is to ensure that
T共x,y,z,t兲兩t=0 = T⬁ 共2兲 pointwise temperatures over the cutting zone exceed the
For the areas of S1, the boundary condition is considered adiabatic softening temperature, say, 1000° C 关24,25兴, because there
and defined by is considerable degradation of hardness and strength over

冏 冏
that temperature for silicon nitride ceramics.
⳵T 共2兲 In this study, the top-hat distribution of laser intensity re-
=0 共3兲
⳵n S1 places the Gaussian distribution in our previous work based
on the laser profile measurement from the manufacturer
In the area of S2, in addition to free convection and thermal 共Visotek Inc.兲. As a result, an approximately uniform heat
radiation, there is also a heat flux from the laser source. Thus the flux input, ql⬙, yields, assuming that the top-hat distribution
boundary condition can be defined as is not altered for the inclination angle of 70 deg between

k 冏 冏
⳵T
⳵n S2,t⬎0
= ql⬙ − q⬙con − qrad
⬙ 共4兲
the laser beam and the top face of the workpiece.
In order to apply the heat flux to the elements within the
elliptic laser spot, it is roughly divided into 30x ⫻ 32z square
where ql⬙ is heat flux from the laser, q⬙con is convective heat flux, divisions due to the laser inclination. The division size 共in
q⬙con = h共Ts − T⬁兲, and qrad
⬙ is radiation heat flux, qrad
⬙ = ␧␴共Ts4 − T4⬁兲. the x and z directions兲, ␦, is the same as the element size 共in
For the area of S3, besides free convection and thermal radia- the x and z directions兲. The relative error between the
tion, there exists generated heat due to plastic deformation and power input for the simulation and the experimental value
tool-workpiece friction in machining. Thus the boundary condi- is 0.5%. Each division is specific to a corresponding ele-
tion can be represented by ment. As the laser spot moves, the location of each division

冏 冏
is changed and the division corresponds to another element.
⳵T In each moving step, the heat flux is applied to every laser-
k ⬙ − q⬙con − qrad
= qgen ⬙ 共5兲
⳵n S3,t⬎t p
beam covered element and removed from every newly un-
covered one. Note that the distance that the laser spot
It should be noted that the surface of S3 moves with the laser moves in each step is equal to the element size.
beam. 共3兲 Material removal in ANSYS is achieved through “killing”
For the areas of S4, only free convection and thermal radiation elements, which are deactivated by multiplying their stiff-
exist and thereby the boundary condition can be expressed as ness 共or conductivity, or other analogous quantity兲 by a

k 冏 冏
⳵T
⳵n S4
= − q⬙con − qrad
⬙ 共6兲
severe reduction factor 共say, 1.0⫻ 10−8兲. All the effects as-
sociated with deactivated elements are set to zero, such as
element loads, mass, damping, specific heat, and others.
But, in the actual material removal process, the milling cut-
2.2 Model Development Using FEA. In this study, the ther- ter contacts the workpiece with only one part of its nose
mal model is developed using the finite element package ANSYS edge 共Fig. 3兲, because the nose radius, r, of the cutter
11.0 关23兴. The dimensions of the model are the same as those of the 共0.787 mm兲 is much larger than the depth of cut of 0.2 mm.
actual workpiece with 4.3 mm in width 共x direction兲, 5.3 mm in It is also noted that the cutter diameter of 76.2 mm is con-
height 共y direction兲, and 48 mm in length 共z direction兲. Because of siderably larger than the workpiece width of 4.3 mm.
symmetry considerations only one-half of the workpiece is used in Therefore, the cutting path on the workpiece can be ap-
the model. As shown in Fig. 2, the z direction is the laser moving proximated as a straight line, and the cross section of the
direction. The region to be covered with a laser beam is a long cutting zone in any y-z plane can be seen in Fig. 3.
quasirectangular area located on the top face of the workpiece. The FEA mesh adopted in this study for the cutting zone

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workpiece surfaces; hence, for simplification, an average
convection coefficient, h̄, is used for the heated workpiece
共Table 1兲. It is calculated by using the empirical correla-
tions of Churchill and Chu 关26兴 for the vertical plate with
external free convection flows and correlations of Goldstein
et al. 关27兴 and Lloyd and Moran 关28兴 for the horizontal
plate 关29兴.
Fig. 4 FEA mesh for the cutting zone
The temperature-dependent emissivity values used in this study,
␧, are obtained according to Touloukian and DeWitt 关30兴 and Sala
is shown in Fig. 4. The element size 共in the x and z direc- 关31兴, which are listed in Table 1 together with a couple of extrapo-
tions兲 and height 共in the y direction兲 are selected to be five lated points for the high and low temperature ends. The data of the
times the feed and half of the depth of cut, respectively. temperature-dependent thermophysical properties of thermal con-
That is, two layers of elements beneath the top face of the ductivity and specific heat were provided by Ceradyne Inc. 共Table
workpiece will be “killed” once the cutter moves forward 1兲.
by five times of the feed. It is should be mentioned that, in The absorptivities of sintered silicon nitrides at 25° C 共wave-
a mesh dependence study with an approximately tenfold length of 937 nm兲 found in literature are 0.72 关32兴 and 0.56–0.75
finer mesh for the cutting zone, the difference in simulation 关30兴. Zhang and Modest 关33兴 recommended 0.85 by measure-
results was found to be about 1.2%, thus justifying the use ments made for a hot-pressed silicon nitride. The laser wavelength
of the course mesh in this study for the sake of computing they used is 1.06 ␮m, which is close to 937 nm in this study.
efficiency. They found that the absorptivity remains almost constant at 0.85
共4兲 Heat generation associated with machining is considered in from 26° C to 1897° C. The above different values of absorptivity
this model. The cutting energy, Ec, from the cutter in each suggest that the surface absorptivity is affected by the composi-
cut can be approximated by the product of the main cutting tions and production process of silicon nitride ceramics. That is,
force, Fc, and the moving length, Lw, as follows: the above values are somewhat not exactly the one our material
Ec = FcLw ⫻ 10−3 共7兲 has. Hence, based on plenty of experimental data, Shen and Lei
关34兴 indirectly obtained the absorptivity of 0.8 for sintered reac-
tion bonded silicon nitride from a validated heat transfer model,
Since the mechanism of heat transfer at the cutting zone in which was carried out via adjusting the absorptivity to match the
LAMill is not fully understood at present, for simplification, the predicted results with the measured ones. Note that the absorptiv-
generated heat is assumed to transfer to the workpiece in a uni- ity is also affected by temperature 关35,36兴. However, the experi-
form heat flux, q⬙gen. The area and the time of heat transfer in one ments of Zhang and Modest 关33兴 depicted that, below the decom-
step, ␦, can be defined by the following equations, respectively: position temperature, the absorptivity of silicon nitride has a very
Ac = 共Lw · DOC兲 ⫻ 10−6 共8兲 small variation.
In addition, it should be mentioned that the surface oxidation
␦ and possibly generated silica 关34兴 are ignored due to the very thin
ts = 共9兲 layer on the top face around the laser spot.
V f /60
Actually, as the laser spot moves one step in simulation, corre-
spondingly there are ␦ / f cuts in the actual machining. Hence, 3 Experimental Setup
combining Eqs. 共7兲–共9兲, q⬙gen can be expressed as The experimental setup for laser assisted milling of silicon ni-
tride is illustrated in Fig. 5. The milling operation is carried out on
Ec ␦ 16.7FcV f
a computer numerical controlled 共CNC兲 machine 共Haas Automa-
⬙ = ␩ h␩ w
qgen · = ␩ h␩ w 共10兲
t sA c f f · DOC tion Inc.兲. A diode laser 共Visotek Inc., DFL500, wavelength 937
where ␩h is the ratio of the cutting energy eventually converted to nm兲 with a top-hat power distribution is used to generate a high
heat and ␩w is the ratio of the generated heat transferred to the power laser beam, which is delivered through the optical fiber and
workpiece. strikes on the workpiece surface at the angle of 70 deg. A dyna-
Note that Eq. 共10兲 is only suitable for simulations. mometer 共Kistler Inc., Type 9257B兲 is fixed on the worktable and
utilized to measure the cutting forces in the x, y, and z directions.
共5兲 Free convection is reasonably assumed for the slow feed The air jet and shield are employed to prevent the optics from
rate of the workpiece 共⬍1.0 mm/ s兲. Localized laser heat- being overheated. The workpiece is clamped with an insulated
ing in LAMill induces nonuniform temperatures on the vise, which is mounted on the dynamometer. An infrared pyrom-

Table 1 Thermal properties of silicon nitride. The values of thermal expansion coefficient,
thermal conductivity and specific heat are provided by Ceradyne Inc.

Thermal Thermal
Temperature expansion conductivity, k Specific heat, c
共5兲
共K兲 Emissivity, ␧ coefficient, ␤ 共W / m K兲 共J / kg K兲

400 0.94共5兲 0.22 25.1 810


600 0.9 0.51 21.4 960
800 0.86 1.20 20.0 1050
1000 0.83 1.93 19.2 1080
1200 0.8 2.62 18.1 1100
1400 0.77 3.40 17.3 1110
1600 0.75共5兲 3.80 17.0 1115
a
Values from Refs. 关32,31兴.
b
Values from extrapolation.

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eter 共Williamson Inc., model 91-20-C-23D兲 with a range
475– 1750° C is used to concurrently measure the workpiece tem-
peratures. Both the pyrometer and the laser are installed through
holders on the spindle. All the data of temperature and force are
digitally recorded by a computer.
Dozens of our experiments demonstrated that there was severe
tool wear in laser assisted face milling of silicon nitride with
commercial carbide mills; therefore, a house-made cutter with
only one tooth and a polycrystalline cubic boron nitride 共PCBN兲
insert was utilized. The purpose of this special design is to sim-
plify the machining process and thus facilitate the analysis, be-
cause it always ensures that only one tooth contacts the workpiece
during the milling process.
Fig. 5 Experimental setup of laser assisted milling Figure 6 shows the initial positions of the laser and the pyrom-
eter spots. Both of them are tangential to the edge of the right end
face of the workpiece. For two reasons the measurement point of
the pyrometer is not selected at the cutting zone on the top face of
the workpiece. One reason is that, as the laser beam shines on the
workpiece, silica bubbles may continuously form on the top face
of the workpiece 关34兴, which may decrease the measurement ac-
curacy of the infrared pyrometer. The other reason is that the
minimum temperature over the cutting zone is of great concern in
this study. Thus, the pyrometer spot is positioned on the side
共front兲 face with a distance of 1.5 mm to the top face.
The Si3N4 workpiece 共Ceradyne Inc., Ceralloy 147-31N兲 is a
sintered reaction bonded ceramic 共⬃8 wt % additives兲 with di-
mensions of 4.3⫻ 5.3⫻ 48 mm3, and its properties are provided
Fig. 6 Positions of laser spot and pyrometer spot by Ceradyne Inc. 共Table 2兲.

4 Simulation Results
4.1 Temperature Distributions of the Workpiece. Simula-
Table 2 Properties of silicon nitride „25° C… „Ceradyne Inc.…
tions are performed with different operating conditions. One typi-
Property Value cal simulation result is illustrated with temperature distributions in
Fig. 7. The cutting length, Lc, is 7.0 mm, and the operating con-
Density 共kg/ m3兲 3200 ditions are Pl = 410 W, Vc = 1.0 m / s, f = 0.024 mm/ tooth/ rev,
Flexural strength 共MPa兲 800 V f = 6 mm/ min, t p = 12 s, Dl = 3.6 mm, DOC= 0.2, and Ll
Elastic modulus 共GPa兲 310 = 0.5 mm.
Poisson ratio 0.27 In Fig. 7, the MN and MX symbols identify the locations of the
Fracture toughness 共MPa m1/2兲 6.0 minimum and maximum temperatures 共the left face of the work-
piece and the laser spot center兲, respectively. Note that the uni-
form interval is used in the contour display. The contour interval,

Fig. 7 Temperature contours of the workpiece obtained from simulation „Pl = 410 W, Vc = 1.0 m / s,
f = 0.024 mm/ tooth/ rev, Vf = 6 mm/ min, tp = 12 s, and Lc = 7.0 mm…

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Fig. 8 Cutting zone and its temperatures: „left… cutting zone, „right… temperatures over
the cutting zone obtained from simulation „Pl = 410 W, Vc = 1.0 m / s, f
= 0.024 mm/ tooth/ rev, Vf = 6 mm/ min, tp = 12 s, and Lc = 7.0 mm…

defined as the difference between two adjacent contour lines, is ence over the cutting zone, is 120° C.
around 140° C. Obviously, the region near the laser spot has Figure 9 illustrates the temperature contours of the back face
higher temperatures 共over 1000° C兲, which is verified by experi- obtained from simulation. Point F is the MTP with a temperature
mental observations. In the experiments, the color of the material of 1165° C. Assuming that another cutting is conducted, all the
in that region turns into red and fades away to the surroundings. operating conditions are the same except that the depth of cut is
The approaching portion of the laser spot continuously absorbs set to be the nose radius of 0.787 mm. Then Point G is the MTP
energy from heat conduction and, as a result, temperatures in- of the new cutting with a temperature of 1147° C. It means that,
crease quickly, while the newly uncovered region is gradually from the thermal aspects, a larger DOC is feasible under the cur-
cooling down due to free convection and thermal radiation. The rent operating conditions. However, from the machining aspects, a
geometrical widths of the contours in the x, y, and z directions are very large DOC may cause severe surface/subsurface damage,
not uniform and instead tend to increase from the laser spot to the which means that too much energy is deposited in the region not
surrounding portion. That is, along the x, y, and z directions, the to be machined. The approach to prevent it is either to increase the
thermal gradients are becoming smaller. Contour display reveals laser power or feed rate or both.
that the laser heat source has a strong influence on the region
around the laser spot and a weaker influence on the region be- 4.2 Effect of Heat Generation on Machining. As mentioned
yond. Section A-A in Fig. 7 passes through the cutting zone at the in Sec. 2.1, another factor that affects the thermal model is heat
top face of the workpiece. generation due to plastic deformation and tool-workpiece friction,
The minimum temperature point 共MTP兲, as the term suggests, which is associated with machining. In this model, heat generation
is defined as the point with the minimum temperature at the cut- is being treated. Although many studies indicate that the value is
ting zone. Usually, it is farthest from the laser spot center among very small, a few of them calculate it in detail. Since the ratio of
the points in the cutting zone. It depends on the relative positions the cutting energy converting to heat, ␩h, and the ratios of the
of the workpiece and the cutter, and it moves with the cutting generated heat transferring to the cutter, the chips, and the work-
zone. The temperatures at the MTPs should be kept higher than piece, respectively, are not well known, in order to assess the
the material softening temperature in the milling process. maximum possible effect of generated heat on the workpiece tem-
Figures 8共a兲 and 8共b兲 illustrate the cutting zone and its tempera- peratures, the model assumes that all the cutting energy is con-
ture contours obtained from simulations, respectively. Due to the verted to heat, which dissipates into the workpiece 共␩h␩w = 1兲.
very small feed, the surface area OCDE is considered here to Equation 共7兲 indicates that the cutting energy is proportional to
represent the temperature distribution for the cutting zone. Point the main cutting force, Fc. Our experimental results show that the
O V is the location of the MTP and Point D is the maximum average main cutting forces with depth of cut of 0.2 mm and
temperature point over the cutting zone. The temperature differ- cutting length of 1 mm are 8.6 N, 6.4 N, and 2.2 N for operating
ence between them, as well as the maximum temperature differ- temperatures of 1140° C, 1320° C, and 1400° C, respectively. As

Fig. 9 Temperature contours obtained on the back face from simulation


„Pl = 410 W, Vc = 1.0 m / s, f = 0.024 mm/ tooth/ rev, Vf = 6 mm/ min, tp = 12 s,
and Lc = 7.0 mm…

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Table 3 Operating conditions of laser assisted face milling of Si3N4

Laser Cutting Feed Preheat Laser-beam Depth Laser-cutter


power Feed speed rate time diameter of cut allowance
共W兲 共mm/tooth/rev兲 共m/s兲 共mm/min兲 共s兲 共mm兲 共mm兲 共mm兲

300 15
Group I 410 0.024 1.0 6 12 3.6 0.2 0.5
470 8

0.012 3
Group II 410 0.024 1.0 6 12 3.6 0.2 0.5
0.048 12

0.5 3
Group III 410 0.024 1.0 6 12 3.6 0.2 0.5
2.0 12

expected, the average cutting force decreases as the operating Vl = V f = Zf · RPM 共11兲
temperature increases. In order to evaluate the effect of heat gen-
eration, the average cutting force of 9.8 N at the operating tem- Because of the relative motion between the laser and the work-
perature of 1400° C is used as an example in this section. The heat piece, Vl is equal to feed rate, V f . For convenience, in this section,
feed rate, V f , will be used rather than the laser moving speed, Vl.
flux q⬙gen thereby yields 2.0⫻ 105 W / m2 according to Eq. 共10兲.
In this study, the parameters of laser power, feed, and cutting
However, comparing the results from considering heat generation
speed are the most important. The parameters of laser-beam diam-
with those not, the temperature discrepancies at the MTP and
eter, depth of cut, tooth number, and laser-cutter allowance are
maximum temperature point over the cutting zone are about
fixed. The measurement points are shown in Fig. 6. The tempera-
0.3° C and 2 ° C, respectively. That is, q⬙gen indeed can be ne- tures at the MTP and maximum temperature point over the cutting
glected. In fact, the heat flux input from the laser source, ql⬙, is zone are also predicted.
about 150 times of q⬙gen under these operating conditions, even Figures 10–14 show the temperature histories under the operat-
with all the cutting energy being assumed to dissipate into the ing conditions in Groups I and II 共Table 3兲. Each of them includes
workpiece. four curves: measurement, simulation, Simu_MTP, and Simu-
4.3 Uncertainty Analysis. There are some uncertainties in- _Max, which represent experimental data, simulation data, pre-
volved in this study. All the uncertainty values are for the reported dicted minimum, and maximum data at the cutting zone, respec-
quantities. These uncertainties originate from both measurements tively. For uncertainty considerations, the curves of measurement
and simulations. For measurements, the uncertainty is mainly and simulation are shown with the error bars. The curves of Si-
from pyrometer system error, ⫾0.5%. For simulations, the uncer- mu_MTP and Simu_Max are not shown with the error bars be-
tainties are mainly from 共1兲 laser-beam diameter determination, cause the difference between Simu_MTP and Simu_Max, as well
⫾11.1%, which comes from the actual measurements of laser- as the maximum temperature difference over the cutting zone, is
beam diameter; 共2兲 the absorptivity of the workpiece 关33兴, ⫾3.2%, the most important. The curves of measurement and simulation
which is due to temperature variations; 共3兲 meshing and discreti- show that the temperatures quickly rise to a peak value and then
zation of the model, 1.2%, which is from model meshing and gradually go down. This is because during preheating, the position
calculations; 共4兲 average convection coefficient 关29兴, ⫾11.8%, of the laser beam is fixed. After that time the measurement spots
which arises from nonuniform temperatures and different convec- start to move with the workpiece. Furthermore, the maximum
tion surfaces of the workpiece; and 共5兲 laser power input, 0.5%, temperature differences over the cutting zone are found to in-
which is due to power difference between the simulation and the crease gradually as the workpiece moves. The reason is that the
experiment 共Sec. 2.2 共2兲兲. The contributions of these uncertainties insulating materials are not ideally adiabatic. The simplified
to the simulation error also rank as above. For example, under the boundary conditions in the model actually neglect the heat trans-
operating conditions Pl = 410 W, Vc = 1.0 m / s, f fer between the insulating materials and the vise, thus causing the
= 0.024 mm/ tooth/ rev, V f = 6 mm/ min, t p = 12 s, Dl = 3.6 mm, predicted temperatures higher than the measured ones. As the tem-
DOC= 0.2, and Lc = 7.0 mm, the temperature at the MTP is
1165° C and the corresponding simulation error has upper and
lower limits of 4.2% and 4.6%, respectively, which are deter-
mined via several simulations using all the possible combinations
of the limit values of the above factors that can result in the
uncertainties in LAMill and then finding the upper and lower lim-
its. In addition, there are some uncertainties neglected in this
model such as inhomogeneous properties of the material, surface
oxidation, the air jet, and the insulating material.

5 Model Validation
To develop confidence in our FEA model, a series of experi-
ments was conducted for validation purposes. Three groups of
them are listed in Table 3. The operating conditions include the
following parameters: laser power, Pl, laser-beam diameter, Dl,
laser moving speed, Vl, preheat time, t p, depth of cut, DOC, feed,
f, cutting speed, Vc, tooth number, Z, and laser-cutter allowance, Fig. 10 Temperature histories with Pl = 300 W „Vc = 1.0 m / s, f
Ll. Vl and V f are linked through the following equation: = 0.024 mm/ tooth/ rev, Vf = 6 mm/ min, and tp = 15 s…

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Fig. 11 Temperature histories with Pl = 410 W „Vc = 1.0 m / s, f Fig. 14 Temperature histories with f = 0.048 mm/ tooth/ rev „Pl
= 0.024 mm/ tooth/ rev, Vf = 6 mm/ min, and tp = 12 s… = 410 W, Vc = 1.0 m / s, Vf = 12 mm/ min, and tp = 12 s…

peratures go up, the heat transfer speed increases and, as a result,


speed and feed are fixed. As expected, the higher the laser power,
the differences further increase. However, once the thermal sys-
the more heat energy the workpiece absorbs, and the higher tem-
tem is in a quasisteady state, the differences tend to maintain a
peratures the workpiece has. The laser power of 470 W has the
constant value, but they are still in the range of error bars shown
highest MTP temperatures among all these three cases. The maxi-
in Figs. 10–14. In addition, it is noted that the maximum tempera-
mum differences over the cutting zone for the powers of 300 W,
ture difference over the cutting zone maintains nearly constant as
410 W, and 470 W are 100° C, 120° C, and 139° C, respectively.
the thermal system is in a quasisteady state condition, which
That is, the thermal gradients inside the cutting zone have a small
means that the thermal gradients inside the cutting zone no longer
increase as the laser power goes up.
change with the workpiece moving.
Figures 13, 11, and 14 show the temperature histories with
Figures 10–12 show the temperature histories with the laser
feeds of 0.012 mm/tooth/rev, 0.024 mm/tooth/rev, and 0.048 mm/
powers of 300 W, 410 W, and 470 W, respectively. The cutting
tooth/rev, respectively. The laser power and cutting speed are
fixed. According to Eq. 共8兲, the feed variation is related to feed
rate variation. Although all the parameters in these three cases are
the same except for the feed and feed rate, the peak temperatures
are different. This is because the peak temperature does not usu-
ally occur at the preheating stage, instead it often happens at some
time after the preheating stage. The value of the peak temperature
depends on feed rate. A smaller feed rate can result in a higher
value. It is noted that the maximum temperature differences over
the cutting zone for these three cases are almost the same. They
are all 120° C. That is, the feed variation does not alter the thermal
gradients inside the cutting zone as feed varies.
In Group III 共Table 3兲, the parameters of laser power and feed
are fixed, and cutting speed changes as 0.5 m/s, 1.0 m/s, and 2.0
m/s, respectively. Similar to the change in feed, cutting speed
variation is also related to feed rate variation. Actually, both cut-
ting speed and feed affect the temperatures via varying feed rate.
However, once the feed rate is fixed, from the thermal aspects,
Fig. 12 Temperature histories with Pl = 470 W „Vc = 1.0 m / s, f they have a little impact on temperatures because their contribu-
= 0.024 mm/ tooth/ rev, Vf = 6 mm/ mn, and tp = 8 s… tions to heat generation are so small that it can be ignored. In fact,
Groups II and III have almost the same thermal results, which are
demonstrated via both experiments and simulations.
In summary, Figs. 10–14 show that the predicted temperature
results are in good agreement with the measured ones. Thus it is
reasonable to declare that the thermal model can successfully pre-
dict temperature distributions of the workpiece under different
operating conditions.

6 Guidelines on Parameter Selection


Three basic criteria are summarized for the smooth operation of
laser assisted milling: 共1兲 The minimum temperatures over the
cutting zone should exceed the material softening temperature in
the milling process, 共2兲 the thermal gradients over the cutting zone
should be as small as possible, and 共3兲 the temperatures of the
workpiece should be lower than the decomposition temperature of
silicon nitride so as to avoid possibly damaging the machined
Fig. 13 Temperature histories with f = 0.012 mm/ tooth/ rev „Pl surface. To this end, the parameters in laser assisted milling
= 410 W, Vc = 1.0 m / s, Vf = 3 mm/ min, and tp = 12 s… should be selected carefully.

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The forgoing analysis shows that the parameters of laser power S2 ⫽ the area covered by the laser beam 共laser spot兲,
and feed rate dominantly determine the temperature distribution of m2
the workpiece. Feed and cutting speed can also play an important S3 ⫽ the areas where the cutter is in contact with
role via varying feed rate. However, once feed rate is fixed, feed the workpiece in one cut, m2
and cutting speed themselves have a little impact on workpiece S4 ⫽ the areas including all the workpiece surfaces
temperature. Hence, to meet the three basic criteria, a high laser open to the surroundings except S2 and S3, m2
power is strongly recommended, but high laser power will in- t ⫽ time, s
crease the thermal gradients inside the cutting zone. Hence, a t p ⫽ preheat time, s
compromise should be made between them. Once laser power is ts ⫽ time for one step movement of laser spot, s
determined, feed rate should be selected appropriately so as to T ⫽ temperature, °C
keep the temperature change as small as possible. According to Ts ⫽ temperature on the surface of the model, °C
Eq. 共11兲, there are three ways to regulate feed rate: feed, spindle T⬁ ⫽ ambient temperature, °C
speed, and tooth number. Vl ⫽ laser moving speed, mm/min
Compared with depth of cut, the feed is so small over the cut-
V f ⫽ feed rate of milling cutter, mm/min
ting zone that the temperature difference can be neglected in the
vol ⫽ the volume of the workpiece, m3
feed direction 共Fig. 3兲. That is, from the thermal aspects, the feed
x , y , z ⫽ rectangular coordinates, m
can be increased appropriately so that the material removal rate
Z ⫽ tooth number of the milling cutter
共MRR兲 can be improved.
It is noted that the nose radius of the milling cutter can also Greek Letters
affect the temperatures at the MTPs. As shown in Fig. 3, the ␣ ⫽ absorptivity of workpiece surface
smaller the nose radius, the shorter the distance from the MTP to ␤ ⫽ volumetric thermal expansion coefficient, K−1
the laser spot, and thus the higher the temperatures at the MTPs. ␦ ⫽ square division of the uniform elements, mm
Thus the nose radius of the milling cutter is expected to be as ␧ ⫽ emissivity of workpiece surface
small as possible. ␳ ⫽ mass density, kg/ m3
␴ ⫽ Stefan–Boltzmann constant
7 Conclusions ␩h ⫽ ratio of the cutting energy converted to heat
A transient three-dimensional heat transfer model for laser as- ␩w ⫽ ratio of the generated heat transferred to the
sisted milling is developed and validated through comparing the workpiece
predicted temperatures with the experimental ones. Simulation re-
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