Need to shape miniature, hard-to-machine parts with three-dimensional micro and meso scale features? Test results at Georgia Institute of Technology show that mechanical micro machining can still be the best way -- if a laser is used to soften the tool path.
In addition to achieving a reduction in cutting force, the researchers expect the laser assist will also benefit cutting speeds and part accuracy as well.
For example, in micro machining of H13 mold steel (42 HRC), researchers have been able to reduce cutting force by as much as 56%.
Researchers say predictive models for temperature and machining force have been validated against experimental data, and work is proceeding to transfer the results to micro milling applications.
The goal, explains Shreyes Melkote, professor of mechanical engineering, is to take advantage of the metal removal potential of mechanical micro machining while minimizing tool deflection and catastrophic tool failure risks. Despite the potential advantages, today's mechanical micro machining technology is limited by the workpiece materials that can be processed and the relatively low stiffness and bending/shear strength of the micro tools, adds John Morehouse, research engineer at Georgia Tech's Manufacturing Research Center (MARC).
