Generic placeholder image

Recent Patents on Engineering

Editor-in-Chief

ISSN (Print): 1872-2121
ISSN (Online): 2212-4047

Review Article

Research Status of Subsequent Machining of Laser Cladding Layers

Author(s): Lei Li*, Yujun Cai, Guohe Li and Meng Liu

Volume 16, Issue 1, 2022

Published on: 25 November, 2020

Article ID: e211221188382 Pages: 10

DOI: 10.2174/1872212115999201125123148

Price: $65

conference banner
Abstract

Background: As an important method of remanufacturing, laser cladding can be used to obtain parts with specific shapes by stacking the materials layer by layer. The formation mechanism of laser cladding determines the “Staircase effect”, which makes the surface quality hardly meet the dimensional accuracy of the parts. Therefore, the subsequent machining must be performed to improve the dimensional accuracy and surface quality of cladding parts.

Methods: In this paper, chip formation, cutting force, cutting temperature, tool wear, surface quality, and optimization of cutting parameters in the subsequent cutting of the laser cladding layer are analyzed. Scholars have expounded and studied these five aspects, but the cutting mechanism of laser cladding needs further research.

Results: The characteristics of the cladding layer are similar to that of difficult-to-machine materials, and the change of parameters have a significant impact on cutting performance.

Conclusion: The research status of subsequent machining of cladding layers is summarized, mainly from the aspects of chip formation, cutting force, cutting temperature, tool wear, surface quality, and cutting parameters optimization. Besides the existing problems and further developments of subsequent machining of cladding layers have been pointed out in this paper. These efforts are helpful in promoting the development and application of laser cladding remanufacturing technology.

Keywords: Laser cladding, subsequent machining, chip formation, cutting force, cutting temperature, tool wear, parameter optimization.

Graphical Abstract

[1]
C.Y. Yu, Research on laser remanufacturing process and performance of important parts of marine equipment., Electromechanical Control Technology and Transportation, 2017.
[2]
X.D. Ren, Laser shock modification and life extension technology., China Machine Press: Beijing, 2011.
[3]
J. Wang, Y. Dong, S. Xu, W. Xia, and X. Yan, "Three-dimensional characterization method of geometric features of single-pass laser cladding layer", China Laser, vol. 37, no. 2, pp. 581-585, 2010.
[http://dx.doi.org/10.3788/CJL20103702.0581]
[4]
Y. Zhao, J. Sun, and J. Li, "Study on chip morphology and milling characteristics of laser cladding layer", Int. J. Adv. Manuf. Technol., vol. 77, no. 5-8, pp. 783-796, 2015.
[http://dx.doi.org/10.1007/s00170-014-6483-2]
[5]
P. Zhang, J. Du, and T. Zhou, "Sustainable manufacturing: re-contouring of laser cladding restored parts by machining method with cutting energy management", Arch. Civ. Mech. Eng., vol. 42, pp. 1-10, 2020.
[6]
G.L. Coz, M. Fischer, and R. Piquard, "Micro Cutting of Ti-6Al-4V Parts Produced by SLM Process", Procedia Cirp, vol. 58, pp. 228-232, 2017.
[http://dx.doi.org/10.1016/j.procir.2017.03.326]
[7]
Y. Shen, "Experimental study on drilling small diameter hole of stainless steel laser cladding parts", Mech. Mechanical Eng., vol. 22, no. 1, pp. 285-294, 2020.
[8]
C. Tian, X. Li, and S. Zhang, "Study on design and performance of metal-bonded diamond grinding wheels fabricated by selective laser melting (SLM)", Mater. Des., vol. 156, pp. 52-61, 2018.
[http://dx.doi.org/10.1016/j.matdes.2018.06.029]
[9]
D. Przestacki, T. Chwalczuk, and S. Wojciechowski, "The study on minimum uncut chip thickness and cutting forces during laser-assisted turning of WC/NiCr clad layers", Int. J. Adv. Manuf. Technol., vol. 91, no. 9-12, pp. 3887-3898, 2017.
[http://dx.doi.org/10.1007/s00170-017-0035-5]
[10]
V. Böß, B. Denkena, V. Wesling, S. Kaierle, F. Rust, D. Nespor, and B. Rottwinkel, "Repairing parts from nickel base material alloy by laser cladding and ball end milling", Prod. Eng., vol. 10, pp. 1-9, 2016.
[11]
B. Wang, Z.Q. Liu, and L.C. Su, "Effects of cutting conditions on the machinability of stainless steel formed by laser cladding", Adv. Mat. Res., vol. 797, pp. 166-171, 2013.
[http://dx.doi.org/10.4028/www.scientific.net/AMR.797.166]
[12]
N. Luo, H.W. Huang, and H.Q. Tong, "Experimental research on the force-force ratio of high-speed grinding of CBN grinding wheels", J. Xiamen Uni. Technol., vol. 03, pp. 22-26, 2007.
[13]
P. Zhang, and Z. Liu, "Machinability investigations on turning of Cr-Ni-based stainless steel cladding formed by laser cladding process", Int. J. Adv. Manuf. Technol., vol. 82, no. 9-12, pp. 1707-1714, 2016.
[http://dx.doi.org/10.1007/s00170-015-7474-7]
[14]
A. Polishetty, M. Shunmugavel, and M. Goldberg, "Cutting force and surface finish analysis of machining additive manufactured titanium alloy Ti-6Al-4V", Procedia Manufacturing, vol. 7, pp. 284-289, 2017.
[http://dx.doi.org/10.1016/j.promfg.2016.12.071]
[15]
M. Shunmugavel, A. Polishetty, and M. Goldberg, "A comparative study of mechanical properties and machinability of wrought and additive manufactured (selective laser melting) titanium alloy-Ti-6Al-4V", Rapid Prototyping J., vol. 23, no. 6, pp. 1051-1056, 2017.
[http://dx.doi.org/10.1108/RPJ-08-2015-0105]
[16]
F. Montevecchi, "Cutting forces analysis in additive manufactured AISI H13 alloy", Procedia Cirp, vol. 46, pp. 476-479, 2016.
[http://dx.doi.org/10.1016/j.procir.2016.04.034]
[17]
W. Ming, J. Chen, and Q. An, "Dynamic mechanical properties and machinability characteristics of selective laser melted and forged Ti6Al4V", J. Mater. Process. Technol., vol. 271, pp. 284-292, 2019.
[http://dx.doi.org/10.1016/j.jmatprotec.2019.04.015]
[18]
Q. Bai, B. Wu, and X. Qiu, "Experimental study on additive/subtractive hybrid manufacturing of 6511 steel: process optimization and machining characteristics", Int. J. Adv. Manuf. Technol., pp. 1-10, 2020.
[19]
M. Salehi, "Study on micro texturing of uncoated cemented carbide cutting tools for wear improvement and built-up edge stabilisation", J. Mater. Process. Technol., vol. 21, no. 5, pp. 62-70, 2015.
[20]
P. Guo, B. Zou, and C. Huang, "Study on microstructure, mechanical properties and machinability of efficiently additive manufactured AISI 316L stainless steel by high-power direct laser deposition", J. Mater. Process. Technol., vol. 240, pp. 12-22, 2017.
[http://dx.doi.org/10.1016/j.jmatprotec.2016.09.005]
[21]
Z.T. Tang, Z.Q. Liu, Y.Z. Pan, Y. Wan, and X. Ai, "The influence of tool flank wear on Residual stresses induced by milling aluminum alloy", J. Mater. Process. Technol., vol. 209, no. 9, pp. 4502-4508, 2009.
[http://dx.doi.org/10.1016/j.jmatprotec.2008.10.034]
[22]
P.L. Cao, Y. Bai, and C.P. Liu, "Theoretical calucation on cutting heat and its influence factors analysis in ice core drilling", J. Northeastern Uni., vol. 36, no. 2, pp. 77-86, 2015.
[23]
M.S.A. Aziz, T. Ueda, and T. Furumoto, "Study on machinability of laser sintered materials fabricated by layered manufacturing system: influence of different hardness of sint ered materials", Procedia Cirp, vol. 4, pp. 79-83, 2012.
[24]
G. Struzikiewicz, W. Zębala, A. Matras, M. Machno, Ł. Ślusarczyk, S. Hichert, and F. Laufer, "Turning research of additive laser molten stainless steel 316l obtained by 3D printing", Materials (Basel), vol. 12, no. 1, p. 182, 2019.
[http://dx.doi.org/10.3390/ma12010182] [PMID: 30621106]
[25]
C. Ma, M. Gao, X.F. Sun, Z.Y. Xie, W.W. Ming, and M. Chen, "Experimental study on drilling performance of 3D printed titanium alloys", Tool Technol., vol. 52, no. 07, pp. 21-23, 2018.
[26]
S. Imbrogno, S. Rinaldi, and A. Raso, "3D FE simulation of semifinishing machining of Ti6Al4V additively manufactured by direct metal laser sintering “ in: AIP Conference Proceedings [Author(s) Proceedings of the 21st international ESAFORM conference on material forming: ESAFORM 2018 - Palermo, Italy, 2018.
[27]
A. Bordin, S. Imbrogno, G. Rotella, S. Bruschi, A. Ghiotti, and D. Umbrello, "Finite element simulation of semi-finishing turning of electron beam melted TI6AL4V under dry and cryogenic cooling", Procedia CIRP J, vol. 31, pp. 551-556, 2015.
[http://dx.doi.org/10.1016/j.procir.2015.03.040]
[28]
H.Q. Bai, Y. Shen, and Y.W. An, "Comparative study on small hole drilling of 304 stainless steel and its laser cladding parts", Applied laser, vol. 1, pp. 1-6, 2020.
[29]
S. Li, D.M. Guo, Q. Bai, and B. Zhang, "Experimental Investigation on Dry Milling of Ti-6Al-4V in Additive/Subtractive Hybrid Manufacturing", The 17th International Manufacturing Conference in China, 2017.
[30]
W. Du, Q. Bai, and B. Zhang, "Machining characteristics of 18Ni-300 steel in additive/subtractive hybrid manufacturing", Int. J. Adv. Manuf. Technol., vol. 95, no. 5-8, pp. 2509-2519, 2018.
[http://dx.doi.org/10.1007/s00170-017-1364-0]
[31]
J. Dang, G. Liu, and Y. Chen, "Experimental investigation on machinability of DMLS Ti6Al4V under dry drilling process", Mater. Manuf. Process., pp. 1-10, 2019.
[http://dx.doi.org/10.1080/10426914.2019.1594254]
[32]
S.Z. Wojciechowski, P. Twardowski, and T. Chwalczuk, "Surface roughness analysis after machining of direct laser deposited tungsten carbide[C] International Conference on Metrology Properties of Engineering Surfaces", J. Phy.: Conference Series, vol. 438, 2014
[33]
K. Yusuf, and K. Ozhan, "Porosity, surface quality, microhardness and microstructure of selective laser melted 316l stainless steel resulting from finish machining", J. Manuf. Mater. Proces., vol. 2, no. 2, p. 36, 2018.
[http://dx.doi.org/10.3390/jmmp2020036]
[34]
T. Wang, Y. Li, and J. Liu, "Milling force and surface topography of ti-6al-4v titanium alloy cladded by the laser", Surf. Rev. Lett., vol. 26, no. 5, p. 1850185, 2019.
[35]
X. Huang, Q. Bai, Y.T. Li, and B. Zhang, "Machining finish of titanium alloy prepared by additive manufacturing[c]", The Second International Conference On Applied Engineering Materials And Mechanics, 2017pp. 43-48
[http://dx.doi.org/10.4028/www.scientific.net/AMM.872.43]
[36]
J.M. Zhou, V. Bushlya, and R.L. Peng, "Effects of tool wear on subsurface deformation of nickel-based superalloy", Procedia Eng., vol. 19, no. 1, pp. 407-413, 2011.
[http://dx.doi.org/10.1016/j.proeng.2011.11.133]
[37]
Y. Zhao, J. Sun, and J.F. Li, "Effect of copper element on the performance of laser cladding of FeCr alloy and its vibration reduction mechanism during milling", China Laser, vol. 42, no. 03, pp. 61-69, 2015.
[38]
H.X. “Research on composite manufacturing process of titanium alloy additive.”, Dalian University of Technology: Dalian, 2017.
[39]
F. Zhao Wei, H.S. Zhang, and H.M. Bai, "Application research on cutting tools of laser cladding rod parts", Coal Min. Machin., vol. 40, no. 09, pp. 151-153, 2019.
[40]
Y.H. Tao, "Analysis of factors affecting roughness of machined surface in cutting process", Sci. Technol. Info., vol. 12, pp. 83-83, 2015.
[41]
T. Wang, N. Li, N. Wang, F. Zhang Li, and J. Tang, "Influence of laser cladding TC4 titanium alloy machining trajectory on surface morphology", Hot Working Technol., vol. 48, no. 08, pp. 138-141, 2019.
[42]
W. Ming, B. Xu, and J. Zhang, "Experimental observations on surface roughness, chip morphology, and tool wear behavior in machining Fe-based amorphous alloy overlay for remanufacture", Int. J. Adv. Manuf. Technol., vol. 67, no. 5-8, pp. 1537-1548, 2013.
[http://dx.doi.org/10.1007/s00170-012-4588-z]
[43]
Franci Čuš Župerl, and Tomaž Irgolič, "Prediction of cutting forces in ball-end milling of multi-layered metal materials", Strojniski Vestnik, vol. 62, no. 6, 2016.
[44]
J.Y. Deng, Q.C. Zheng, and G.B. Xue, "Study on cutting force of titanium alloy based on BP neural network", J. Tianjin Uni. Technol., vol. 33, no. 1, pp. 11-15, 2017.
[45]
X. Chen, “Study on the surface roughness prediction model of milling of SLM forming parts and its parameter optimization.” Wuhan University of Science and Technology: Wuhan, 2018.
[46]
M. Ma, "Surface roughness prediction of 304 stainless steel turning based on evolutionary neural network", Light industry machinery, vol. 37, no. 6, pp. 44-47, 2019.

Rights & Permissions Print Cite
© 2024 Bentham Science Publishers | Privacy Policy