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Numerical Modeling and Experimental Study of Laser Assisted Machining of Fused Silica

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Abstract

Fused silica is a kind of high-strength optical material, which is widely used in industry. It is slow and inefficient to process hard and brittle materials by conventional machining (CM) methods, while laser-assisted machining (LAM) technology can improve the plastic cutting ability of materials by local heating and softening, despite its application was not yet carried out in the case of fused silica. In this paper, the smoothed particle hydrodynamics (SPH) method is used to simulate the LAM process of fused silica. The result of LAM simulations show that the chips consist of continuous and discontinuous regions, which is significantly different from the CM in which the crack propagates and breaks in the initial deformation region. This indicates that the material removal mechanism takes place in a hybrid mode, which is a mixture of a brittle fracture and a plastic deformation. And the effect of process parameters on machining surface integrity, tool stress and tool wear were studied by numerical model. Both the simulations and the experimental results demonstrate that LAM significantly improves the machinability of fused silica by reducing the cutting force, improving the machining quality and decreasing the tool wear.

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Data Availability

Data supporting the findings are found within the manuscript. Raw data files will be provided by the corresponding author upon request.

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Acknowledgements

The authors thank the Analytical and Testing Center of Huazhong University of Science and Technology. The authors are also thankful to Mr. Zuohui Yang and Mr. Chuangting Lin for providing help for the SEM analysis for this research work.

Funding

This work was supported by China Postdoctoral Science Foundation (grant No. 2020M682912 ), Major Project of Science and Technology Innovation Committee in Shenzhen (grant No. key 20200206 ) and National Natural Science Foundation of China (grant No. 51627807, 51705172, 51905195).

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Authors and Affiliations

  1. State Key Laboratory of Digital Manufacturing Equipment & Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China

    Huawei Song, Pengfei Pan & Jianfeng Xu

  2. GEM Co., Ltd., Shenzhen, 518101, China

    Huawei Song, Kaihua Xu, Yuping Zhang, Zhengxin Yang & Shaohua Qiao

  3. National Engineering Research Center of WEEE Recycling, Jingmen, 448000, China

    Kaihua Xu, Yuping Zhang, Zhengxin Yang & Shaohua Qiao

Authors
  1. Huawei Song
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  2. Pengfei Pan
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  3. Kaihua Xu
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  4. Yuping Zhang
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  5. Zhengxin Yang
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  6. Shaohua Qiao
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  7. Jianfeng Xu
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Contributions

All authors contributed to the study conception and design. HS is the main project leader, he conceived the idea of research on LAM of fused silica and involved in drafting manuscript. PP mainly performed all experiment procedures and data analyses, and drafted the manuscript. KX and YZ completed the establishment of thermal model and cutting model respectively, and carried out the corresponding data analysis. ZY handled the literature review, drafted the manuscript and edited it for the final submission. SQ utilized SEM to complete the analysis of cutting tool, machined surface and chip morphology. JX is co-leader of this project, involved in drafting, editing, and revised the manuscript. All authors have read and approved the final manuscript.

Corresponding author

Correspondence to Jianfeng Xu.

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The authors declare that the research was conducted in the absence of any commercial or financial relationships that could be construed as a potential conflict of interest.

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Song, H., Pan, P., Xu, K. et al. Numerical Modeling and Experimental Study of Laser Assisted Machining of Fused Silica. Silicon 14, 2975–2988 (2022). https://doi.org/10.1007/s12633-021-01079-3

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  • DOI: https://doi.org/10.1007/s12633-021-01079-3

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