Laser Beam Micro-milling of Micro-channels in Aerospace Alloys

368 Pages·2017·15.09 MB·English

by  Saied Muhammed Hassan Darwish

Advanced Structured Materials
Saied Muhammed Hassan Darwish
Naveed Ahmed
Abdulrahman M. Al-Ahmari E ditors
Laser Beam
Micro-milling of
Micro-channels
in Aerospace
Alloys
Advanced Structured Materials
Volume 68
Series editors
Andreas Öchsner, Southport Queensland, Australia
Lucas F.M. da Silva, Porto, Portugal
Holm Altenbach, Magdeburg, Germany
More information about this series at http://www.springer.com/series/8611
Saied Muhammed Hassan Darwish
Naveed Ahmed Abdulrahman M. Al-Ahmari
(cid:129)
Editors
Laser Beam Micro-milling
of Micro-channels
in Aerospace Alloys
123
Editors
SaiedMuhammed Hassan Darwish and
Princess Fatima Alnijris’s Research Chair
forAdvanced Manufacturing Technology DepartmentofIndustrialandManufacturing
(FARCAMT), AdvancedManufacturing Engineering(IME)
Institute (AMI), Industrial Engineering University of Engineering andTechnology
Department(IED) (UET)
KingSaud University (KSU) Lahore
Riyadh Pakistan
SaudiArabia
Abdulrahman M.Al-Ahmari
Naveed Ahmed Princess Fatima Alnijris’s Research Chair
Princess Fatima Alnijris’s Research Chair forAdvanced Manufacturing Technology
forAdvanced Manufacturing Technology (FARCAMT), AdvancedManufacturing
(FARCAMT), AdvancedManufacturing Institute (AMI), Industrial Engineering
Institute (AMI), Industrial Engineering Department(IED)
Department(IED) KingSaud University (KSU)
KingSaud University (KSU) Riyadh
Riyadh SaudiArabia
SaudiArabia
ISSN 1869-8433 ISSN 1869-8441 (electronic)
AdvancedStructured Materials
ISBN978-981-10-3601-9 ISBN978-981-10-3602-6 (eBook)
DOI 10.1007/978-981-10-3602-6
LibraryofCongressControlNumber:2016963630
©SpringerNatureSingaporePteLtd.2017
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Acknowledgements
InTheNameofAllah,TheMostBeneficent,TheMostMerciful
First of all, I praise and express my heartiest gratitude to the most merciful
Almighty ALLAH who has given me strength and ability to write this book.
Without His help, it would have been impossible to conduct this research and
compile this draft.
TheauthorswouldliketoacknowledgethePrincessFatimaAlnijris’sResearch
Chair for Advanced Manufacturing Technology (FARCAMT), Vice Deanship of
Research Chairs, King Saud University, Saudi Arabia for financial support of this
project.
v
Contents
Introduction .. .... .... .... .... ..... .... .... .... .... .... ..... 1
Literature Review.. .... .... .... ..... .... .... .... .... .... ..... 15
Research Methodology.. .... .... ..... .... .... .... .... .... ..... 81
Under-Water Laser Beam Micro-milling (UWLBMM)
of Aerospace Alloys .... .... .... ..... .... .... .... .... .... ..... 101
Dry Laser Beam Micro-milling (DLBMM) of Aerospace Alloys.. ..... 133
Dimensional Variations in DLBMM of Aerospace Alloys... .... ..... 171
Mathematical Modeling and Multi-objective Optimization .. .... ..... 201
Validations—Modeling and Optimization.... .... .... .... .... ..... 241
Conclusions and Future Work Recommendations. .... .... .... ..... 259
Appendix A... .... .... .... ..... .... .... .... .... .... ..... .... 265
Appendix B... .... .... .... ..... .... .... .... .... .... ..... .... 313
References.... .... .... .... ..... .... .... .... .... .... ..... .... 327
vii
Abbreviations
AA Aluminum alloy
CFRP Carbon fiber reinforced polymers
CM Conventional machining
DLBMM Dry laser beam micro-milling
EDM Electric discharge machining
EDS Energy dispersive X-ray spectroscopic
FCCCD Face centered central composite design
HAZ Heat affected zone
HVA Vicker’s hardness
LAECM Laser assisted electrochemical machining
LAM Laser assisted machining
LBM Laser beam machining
LBMM Laser beam micro-milling
LCM/E Laser chemical machining/etching
MRR Material removal rate
NA Nickel alloy
NCM Non-conventional machining
Nd:YAG Neodymium-doped yttrium aluminum garnet; Nd:Y Al O
3 5 12
Nd:YVO Neodymium-doped yttrium orthovanadate
4
NP Nanoparticle
PC Polycarbonate
PMMA Poly-methyl methacrylate
RL Recast layer
RSM Response surface methodology
SEM Scanning electron microscopy
SiC Silicon carbide
TA Titanium alloy
TFTPs Thin film thermocouples
ix
x Abbreviations
UV Ultra Violet
UWLBMM Underwater laser beam micro-milling
WEDM Wire-electric discharge machining
Nomenclature
µ Dynamic viscosity (Ns/m2)
A Area of water container base (mm2)
wc
AXB Actual bottom width (µm)
AXT Actual top width (µm)
AZ Actual depth (µm)
Ah Actual taper angle (degree)
C Specific heat capacity (J/kg °C)
p
DXB Designed bottom width (µm)
DXT Designed top width (µm)
DZ Designed depth (µm)
Dh Designed taper angle (degree)
f Pulse frequency (kHz)
FR Feed rate (µm/laser scan)
I actual transmitted intensity (kW/mm2)
I Intensity above water film (kW/mm2)
o
K Thermal conductivity (W/m °C)
Ø Spot diameter (µm)
PPP Pulse peak power (MW/s)
T Melting temperature (°C)
m
t Average water film thickness (mm)
w
V Scan speed (mm/s)
V Volume of substrate (mm3)
s
V Total volume of water required (mm3)
total
V Volume of water at the substrate (mm3)
w
V Volume of water container (mm3)
wc
V Volume of water film layer t (mm3)
wl w
a Absorption coefficient of water (cm−1)
w
DXB Variation in bottom width (%)
DXT Variation in top width (%)
DZ Variation in depth (%)
s Wavelength (nm)
List of Figures
Chapter 1 Introduction
Figure 1 Overview of laser machining processes [3]. . . . . . . . . . . . . 2
Figure 2 Function principle of Q-switching . . . . . . . . . . . . . . . . . . . 4
Figure 3 Various mechanisms of laser ablation [6] . . . . . . . . . . . . . . 6
Figure 4 Microfluidic device and micro-channel heat
exchanger [20] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 5 Research methodology in general . . . . . . . . . . . . . . . . . . . 11
Chapter 2 Literature Review
Figure 1 Nanosecond and longer pulse laser ablation [66]. . . . . . . . . 18
Figure 2 Temperature distribution along the x-axis and y-axis at
different heating periods [93] . . . . . . . . . . . . . . . . . . . . . . 24
Figure 3 Recast layer piling procedure according to the scanning
repeat count [101]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 4 Laser machining of a Al O , b Si N , c SiC
2 3 3 4
and d MgO [102] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 5 Configuration of laser cutting system with the
dual-laser-beam method [86]. . . . . . . . . . . . . . . . . . . . . . . 29
Figure 6 Effect of cutting speed on cutting forces for conventional
and LAM machining (feed = 0.25 mm/rev) [131] . . . . . . . . 33
Figure 7 Damageinthecuttingtoolwhenthelaserbeamisfocused
at a circumferential distance of 25 mm from the cutting
tool [132]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 8 Comparison of conventional and LAM tool wear
[138]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 9 Variation of material removal temperature with laser
power [144] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 10 Nano-holes. a–c Laser irradiation power 5, 6 and 7.3 W,
respectively, d count of nano-hole size distribution and
xi