Micro end milling is a fast and direct method of creating net-shaped functional microparts, micromolds, and prototypes. However, the small flexural stiffness, strength, and hardness of the tool limit the efficiency of machining. It is not expected that a new material with increased hardness and yield strength will be developed in the near future that significantly improves the durability for tools manufactured with diameters in the tens to hundreds of microns. To enable a significant increase in performance and productivity requires higher spindle speeds and increased chiploads. However, an increase in chipload is inhibited by the small flexural stiffness and strength of the tools: a direct result of the tool diameter. Laser-assisted micro end milling has the potential to increase the chipload and productivity by locally reducing the workpiece material’s yield strength at the cutting location. This study examines the effect of laser preheating on micro end milling of 6061-T6 aluminum and 1018 steel. Two-flute, , carbide end mills are used to cut deep slots at a spindle speed of . The laser power and chipload are varied to show their effect on cutting forces, specific cutting energy, burr formation, surface finish, and temperature. The results are compared to the average material removal temperature given by predictions made from a heat transfer model of the workpiece undergoing laser preheating. Results indicate that chipload and productivity can be significantly increased during dry machining of 6061-T6 aluminum and 1018 steel by localized preheating of the workpiece.
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e-mail: pfefferk@engr.wisc.edu
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February 2008
Research Papers
Effect of Laser Preheating the Workpiece on Micro end Milling of Metals
Yongho Jeon,
Yongho Jeon
Department of Mechanical Engineering,
University of Wisconsin
, Madison, Madison, WI 53706
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Frank Pfefferkorn
Frank Pfefferkorn
Department of Mechanical Engineering,
e-mail: pfefferk@engr.wisc.edu
University of Wisconsin
, Madison, Madison, WI 53706
Search for other works by this author on:
Yongho Jeon
Department of Mechanical Engineering,
University of Wisconsin
, Madison, Madison, WI 53706
Frank Pfefferkorn
Department of Mechanical Engineering,
University of Wisconsin
, Madison, Madison, WI 53706e-mail: pfefferk@engr.wisc.edu
J. Manuf. Sci. Eng. Feb 2008, 130(1): 011004 (9 pages)
Published Online: January 30, 2008
Article history
Received:
April 18, 2006
Revised:
August 5, 2007
Published:
January 30, 2008
Citation
Jeon, Y., and Pfefferkorn, F. (January 30, 2008). "Effect of Laser Preheating the Workpiece on Micro end Milling of Metals." ASME. J. Manuf. Sci. Eng. February 2008; 130(1): 011004. https://doi.org/10.1115/1.2783219
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