Laser-Assisted Milling of Silicon Nitride Ceramics and Inconel 718

Laser-assisted machining (LAM) has shown its potential to significantly reduce fabrication costs and improve product quality for advanced materials. While extensive studies have been conducted on laser-assisted turning of various ceramics and high temperature alloys, few attempts have been made to extend LAM to milling operations. In this paper, a transient, three-dimensional thermal model developed for laser-assisted milling (LAML) is presented and its accuracy is verified by surface temperature measurements with an infrared camera. LAML experiments designed by the model are successfully conducted on silicon nitride ceramics using TiAlN coated carbide end mills and Inconel 718 using SiC reinforced alumina cutting tools. The promising experimental results, including good surface roughness and acceptable tool wear, show the validation of applying the thermal model to design LAML processes and the feasibility of employing LAML for difficult-to-machine materials such as advanced ceramics and superalloys.