Simulation and Experimental Analysis of Tool Wear and Surface Roughness in Laser Assisted Machining of Titanium Alloy

Abstract

A three-dimensional cutting simulation prediction model based on DEFORM-3D finite element software was developed and experimentally validated, with a maximum error of 21.1% between the experimental and simulation results. The effects of the difference in cutting mechanism between conventional machining (CM) and laser-assisted machining (LAM) of TC6 titanium alloy on the tool wear and the surface roughness were investigated in terms of the cutting force and the cutting temperature. The depth of the laser-heated layer was mainly responsible for the difference in the cutting mechanism between the two methods. When the depth of the heating layer was smaller than the cutting depth, the tool wear of the LAM was larger than that of the CM. When the depth of the heating layer was larger than the cut depth, the surface roughness of the LAM was higher than that of the CM. Range analysis revealed that the cutting speed had the largest effect on the maximum wear depth of the rake face. Based on linear regression analysis, the cutting depth had a larger effect on the surface roughness in LAM. The average error between the linear regression prediction equation and the experimental results for surface roughness was 4.30%.