Download or read book Numerical Modeling and Experimental Investigation of Laser assisted Machining of Silicon Nitride Ceramics written by Xinwei Shen and published by . This book was released on 2010 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser-assisted machining (LAM) is a promising non-conventional machining technique for advanced ceramics. However, the fundamental machining mechanism which governs the LAM process is not well understood so far. Hence, the main objective of this study is to explore the machining mechanism and provide guidance for future LAM operations. In this study, laser-assisted milling (LAMill) of silicon nitride ceramics is focused. Experimental experience reveals that workpiece temperature in LAM of silicon nitride ceramics determines the surface quality of the machined workpiece. Thus, in order to know the thermal features of the workpiece in LAM, the laser-silicon nitride interaction mechanism is investigated via heating experiments. The trends of temperature affected by the key parameters (laser power, laser beam diameter, feed rate, and preheat time) are obtained through a parametric study. Experimental results show that high operating temperature leads to low cutting force, good surface finish, small edge chipping, and low residual stress. The temperature range for brittle-to-ductile transition should be avoided due to the rapid increase of fracture toughness. In order to know the temperature distribution at the cutting zone in the workpiece, a transient three-dimensional thermal model is developed using finite element analysis (FEA) and validated through experiments. Heat generation associated with machining is considered and demonstrated to have little impact on LAM. The model indicates that laser power is one critical parameter for successful operation of LAM. Feed and cutting speed can indirectly affect the operating temperatures. Furthermore, a machining model is established with the distinct element method (or discrete element method, DEM) to simulate the dynamic process of LAM. In the microstructural modeling of a [Beta]-type silicon nitride ceramic, clusters are used to simulate the rod-like grains of the silicon nitride ceramic and parallel bonds act as the intergranular glass phase between grains. The resulting temperature-dependent synthetic materials for LAM are calibrated through the numerical compression, bending and fracture toughness tests. The machining model is also validated through experiments in terms of cutting forces, chip size and depth of subsurface damage.
Download or read book Experimental and Numerical Investigation of Laser Assisted Milling of Silicon Nitride Ceramics written by Budong Yang and published by . This book was released on 2009 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: This study experimentally and numerically investigates laser assisted milling (LAMill) of silicon nitride ceramics. Experiments are conducted to study the machinability of Si3N4 under LAMill. The effects of temperature on cutting forces, tool wear, surface integrity, edge chipping and material removal mechanisms are investigated. It is shown that when temperature increases, cutting force and tool wear are significantly decreased, surface integrity is improved, chip size is increased and material removal demonstrates more plastic characteristics. The mechanisms of edge chipping at elevated temperature are investigated theoretically and experimentally. When temperature is above the softening point and below the brittle/ductile transition temperature, the mechanism is mainly through softening. When temperature is above the brittle/ductile transition temperature, toughening mechanism contributes significantly to the reduced edge chipping. The coupled effect of softening and toughening mechanisms shows that temperature range between 1200 to 1400°C has the most significant effect to reduce edge chipping. Distinct element method (DEM) is applied to simulate the micro-mechanical behavior of Si3N4. First, quantitative relationships between particle level parameters and macro-properties of the bonded particle specimens are obtained, which builds a foundation for simulation of Si3N4. Then, extensive DEM simulations are conducted to model the material removal of machining Si3N4. The simulation results demonstrate that DEM can reproduce the conceptual material removal model summarized from experimental observations, including the initiation and propagation of cracks, chip formation process and material removal mechanisms. It is shown that material removal is mainly realized by propagation of lateral cracks in machining of silicon nitride. At the elevated temperature under laser assisted machining, lateral cracks are easier to propagate to form larger machined chips, there are fewer and smaller median cracks therefore less surface/subsurface damage, and crushing-type material removal is reduced. The material removal at elevated temperature demonstrates more plastic characteristics. The numerical results agree very well with experimental observations. It shows that DEM is a promising method to model the micro-mechanical process of machining Si3N4.
Download or read book Thermal Study of Laser assisted Machining of Silicon Nitride written by Sepehr Omidi and published by . This book was released on 2015 with total page 86 pages. Available in PDF, EPUB and Kindle. Book excerpt: Over the last decades Laser Assisted Machining (LAM) of hard materials has grown into a viable solution for the manufacturing industry. Interest in the machining of ceramics has grown due to the possibilities of LAM reducing tool wear and increasing productivity. The concept is based on heating the ceramic material into a soft phase that makes it much easier to machine. The other advantage this technology has over traditional grinding is that is possible to make complex shapes and even machine threads. While there has been research in LAM of ceramics such as Silicon Nitride, Zirconia, Alumina it often lacks comprehensive analysis for a particular laser source. In order for industry to adopt such a technology an optimized approach to providing results on ceramics is required. A few years ago as a result of ongoing research at NIU the commercial technology Easy to Machine Hard Materials (EMHM(TM)) was developed to address this issue. While research of Silicon Nitride, Zirconia, Alumina and Cemented Carbide are ongoing via EMHM the thrust of this research will be to provide a comprehensive approach and reduce the time required to optimize parameters for machining ceramics. The main issue to address for productivity in industry (when machining) is how to minimize tool wear (so tools last longer) while removing as much material as quickly as possible. This will obviously vary based on material and energy available. To experimentally carry all this work out would require a vast amount of resources and time. As such this proposal discusses the development of an easy to use ANSYS simulation program that will enable the user to see the surface temperature (which can translate to tool life) based on the feed rate, depth of cut, laser power and spindle speed. There are complex thermo-mechanical forces at play and so an optimized program is required to improve throughput of the analysis. We will develop the first generation ANSYS simulation which will help us verify experimental work we have done with the materials that have been researched via EMHM(TM).
Download or read book Theoretical Study of Laser assisted Machining on Silicon Nitride Hollow Ceramic Cylinder Using Finite Element Method written by Mohammed Mudassar Hussain Ansari and published by . This book was released on 2018 with total page 57 pages. Available in PDF, EPUB and Kindle. Book excerpt: The most commonly used technique for machining ceramics is diamond grinding. It accounts for up to 75% of the manufacturing costs resulting in high cost of the product. An LED bulb offering increased brightness, energy saving and long life by using ceramic integration to LED chips costs around 10 times to a normal LED bulb. Complex geometries used in electronics, medical surgeries, aerospace, and automobile industries require the use of costly molds or powder metallurgy for low batch production which does not justify the cost. Laser Assisted Machining (LAM) is a process that uses a laser to locally heat the surface of a component (made of ceramic), making it more ductile and machinable using conventional machine tools. Recent studies have shown that LAM gives improved material removal rate and surface finishing, and reduces the cost of machining, i.e. around 50% reduction in the manufacturing costs. Physical experiments require the use of advanced instruments and specialized tools making it a difficult and time-consuming process. It is necessary to have a predicting thermal study to help design more efficient physical experiments. In this study, Finite Element Analysis (FEA) has been used to analyze the thermal distribution of a workpiece under rotating and translating moving heat source. In LAM, there are many variables that greatly affect the temperature, such as laser size, laser power, translational velocity, etc. Extensive research has been performed on solid cylinders however many new applications such as thermocouple protection tube, cylinder lining, blasting nozzles, bone fusion in surgeries, etc., require application of hollow cylinders. Therefore, this work intends to perform a thermal study on a ceramic tube when a laser beam moving on its outer surface. As the generated heat due to the machining is insignificant compared to the heat created by the laser heat source, this study doesn't consider the mechanical removal of the material. The ceramic chosen for this study is Silicon Nitride as it is widely used due to its excellent wide range of properties making it suitable for all industries. The FEA method and assumptions that will be used on this research has been verified with previous experimental and numerical research on a solid cylinder.
Download or read book Optical Measurements Modeling and Metrology Volume 5 written by Tom Proulx and published by Springer Science & Business Media. This book was released on 2011-05-27 with total page 412 pages. Available in PDF, EPUB and Kindle. Book excerpt: Optical Measurements, Modeling, and Metrology represents one of eight volumes of technical papers presented at the Society for Experimental Mechanics Annual Conference on Experimental and Applied Mechanics, held at Uncasville, Connecticut, June 13-16, 2011. The full set of proceedings also includes volumes on Dynamic Behavior of Materials, Mechanics of Biological Systems and Materials, Mechanics of Time-Dependent Materials and Processes in Conventional and Multifunctional Materials; MEMS and Nanotechnology; Experimental and Applied Mechanics, Thermomechanics and Infra-Red Imaging, and Engineering Applications of Residual Stress.
Download or read book An Experimental Study of Laser Assisted Milling of Silicon Nitride Ceramic written by Shuting Lei PhD and published by . This book was released on 2000 with total page 10 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Download or read book Comprehensive Materials Processing written by and published by Newnes. This book was released on 2014-04-07 with total page 5485 pages. Available in PDF, EPUB and Kindle. Book excerpt: Comprehensive Materials Processing, Thirteen Volume Set provides students and professionals with a one-stop resource consolidating and enhancing the literature of the materials processing and manufacturing universe. It provides authoritative analysis of all processes, technologies, and techniques for converting industrial materials from a raw state into finished parts or products. Assisting scientists and engineers in the selection, design, and use of materials, whether in the lab or in industry, it matches the adaptive complexity of emergent materials and processing technologies. Extensive traditional article-level academic discussion of core theories and applications is supplemented by applied case studies and advanced multimedia features. Coverage encompasses the general categories of solidification, powder, deposition, and deformation processing, and includes discussion on plant and tool design, analysis and characterization of processing techniques, high-temperatures studies, and the influence of process scale on component characteristics and behavior. Authored and reviewed by world-class academic and industrial specialists in each subject field Practical tools such as integrated case studies, user-defined process schemata, and multimedia modeling and functionality Maximizes research efficiency by collating the most important and established information in one place with integrated applets linking to relevant outside sources
Download or read book Advanced Processing and Manufacturing Technologies for Structural and Multifunctional Materials IV written by Tatsuki Ohji and published by John Wiley & Sons. This book was released on 2010-11-23 with total page 260 pages. Available in PDF, EPUB and Kindle. Book excerpt: This issue contains 25 invited and contributed papers, all peer reviewed according to the American Ceramic Society Review Process. The latest developments in processing and manufacturing technologies are covered, including green manufacturing, smart processing, advanced composite manufacturing, rapid processing, joining, machining, and net shape forming technologies. These papers discuss the most important aspects necessary for understanding and further development of processing and manufacturing of ceramic materials and systems.
Download or read book Investigation of Laser Assisted Modification of Silicon Nitride Ceramic for Enhanced Surface Integrity written by Li Sun and published by . This book was released on 2000 with total page 10 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Download or read book Modern Manufacturing Engineering written by J. Paulo Davim and published by Springer. This book was released on 2015-06-19 with total page 323 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book covers recent research and trends in Manufacturing Engineering. The chapters emphasize different aspects of the transformation from materials to products. It provides the reader with fundamental materials treatments and the integration of processes. Concepts such as green and lean manufacturing are also covered in this book.
Download or read book Modern Manufacturing Processes written by Muammer Koç and published by John Wiley & Sons. This book was released on 2019-09-04 with total page 549 pages. Available in PDF, EPUB and Kindle. Book excerpt: Provides an in-depth understanding of the fundamentals of a wide range of state-of-the-art materials manufacturing processes Modern manufacturing is at the core of industrial production from base materials to semi-finished goods and final products. Over the last decade, a variety of innovative methods have been developed that allow for manufacturing processes that are more versatile, less energy-consuming, and more environmentally friendly. This book provides readers with everything they need to know about the many manufacturing processes of today. Presented in three parts, Modern Manufacturing Processes starts by covering advanced manufacturing forming processes such as sheet forming, powder forming, and injection molding. The second part deals with thermal and energy-assisted manufacturing processes, including warm and hot hydrostamping. It also covers high speed forming (electromagnetic, electrohydraulic, and explosive forming). The third part reviews advanced material removal process like advanced grinding, electro-discharge machining, micro milling, and laser machining. It also looks at high speed and hard machining and examines advances in material modeling for manufacturing analysis and simulation. Offers a comprehensive overview of advanced materials manufacturing processes Provides practice-oriented information to help readers find the right manufacturing methods for the intended applications Highly relevant for material scientists and engineers in industry Modern Manufacturing Processes is an ideal book for practitioners and researchers in materials and mechanical engineering.
Download or read book Hybrid Machining written by Xichun Luo and published by Academic Press. This book was released on 2018-06-27 with total page 328 pages. Available in PDF, EPUB and Kindle. Book excerpt: Hybrid Machining: Theory, Methods, and Case Studies covers the scientific fundamentals, techniques, applications and real-world descriptions of emerging hybrid machining technology. This field is advancing rapidly in industrial and academic contexts, creating a great need for the fundamental and technical guidance that this book provides. The book includes discussions of basic concepts, process design principles, standard hybrid machining processes, multi-scale modeling approaches, design, on-machine metrology and work handling systems. Readers interested in manufacturing systems, product design or machining technology will find this one-stop guide to hybrid machining the ideal reference. - Includes tables of recommended processing parameters for key engineering materials/products for each hybrid machining process - Provides case studies covering real industrial applications - Explains how to use multiscale modeling for hybrid machining
Download or read book Intelligent Energy Field Manufacturing written by Wenwu Zhang and published by CRC Press. This book was released on 2018-10-03 with total page 987 pages. Available in PDF, EPUB and Kindle. Book excerpt: Edited by prominent researchers and with contributions from experts in their individual areas, Intelligent Energy Field Manufacturing: Interdisciplinary Process Innovations explores a new philosophy of engineering. An in-depth introduction to Intelligent Energy Field Manufacturing (EFM), this book explores a fresh engineering methodology that not only integrates but goes beyond methodologies such as Design for Six Sigma, Lean Manufacturing, Concurrent Engineering, TRIZ, green and sustainable manufacturing, and more. This book gives a systematic introduction to classic non-mechanical manufacturing processes as well as offering big pictures of some technical frontiers in modern engineering. The book suggests that any manufacturing process is actually a process of injecting human intelligence into the interaction between material and the various energy fields in order to transfer the material into desired configurations. It discusses technological innovation, dynamic M-PIE flows, the generalities of energy fields, logic functional materials and intelligence, the open scheme of intelligent EFM implementation, and the principles of intelligent EFM. The book takes a highly interdisciplinary approach that includes research frontiers such as micro/nano fabrication, high strain rate processes, laser shock forming, materials science and engineering, bioengineering, etc., in addition to a detailed treatment of the so called "non-traditional" manufacturing processes, which covers waterjet machining, laser material processing, ultrasonic material processing, EDM/ECM, etc. Filled with illustrative pictures, figures, and tables that make technical materials more absorbable, the book cuts across multiple engineering disciplines. The majority of books in this area report the facts of proven knowledge, while the behind-the-scenes thinking is usually neglected. This book examines the big picture of manufacturing in depth before diving into the deta
Download or read book Numerical and Experimental Investigation of Interactive Effects in Laser Machining written by Kai Chen and published by . This book was released on 1999 with total page 340 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Download or read book SME Technical Paper written by Society of Manufacturing Engineers and published by . This book was released on 2005 with total page 502 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Download or read book Experimental and Numerical Analyses of Ductile Regime Machining of Silicon Nitride written by Satya Kumar Ajjarapu and published by . This book was released on 2004 with total page 240 pages. Available in PDF, EPUB and Kindle. Book excerpt: Developments in precision machining technology have shown that ductile regime machining of advanced ceramics such as Silicon Nitride (Si[subscript]3N[subscript]4) is possible under controlled cutting conditions. In the present work, the mechanics of ductile regime machining of silicon nitride at micron level depths was studied experimentally and numerically. Machining tests were carried out for depths of cut ranging from 250 nm to 10 [mu]m on Diamond Turning Machine (DTM). Force and surface roughness data collected from diamond turning of silicon nitride samples were presented. Chip morphology studies were also carried out using Scanning Electron Microscopy (SEM) for the machined samples. The mechanical behavior of silicon nitride is treated using the Drucker-Prager yield criterion and implemented in the commercial machining software AdvantEdge. Numerical simulations were conducted for depths of cut ranging from 1 [mu]m to 40 [mu]m and at rake angles from 0[superscript]o to -60[superscript]o. Pressure distribution at the tool and workpiece interface for different depths of cut and rake angles was studied. Experimental results were correlated with the numerical results for -5[superscript]o and -45[superscript]o rake angles.
Download or read book Laser Assisted Waterjet Microgrooving of Silicon Nitride Ceramics with near Damage Free written by and published by . This book was released on 2016 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt:
