Surface generation of tungsten carbide in laser-assisted diamond turning

• Published in: International journal of machine tools & manufacture 2021-09, Vol.168, p.103770, Article 103770
• Main Authors: You, Kaiyuan, Fang, Fengzhou, Yan, Guangpeng
• Format: Article
• Language: English
• Subjects: Boundary conditions; Cutting force; Cutting parameters; Diamond machining; Elastic recovery; High temperature; Laser beam annealing; Laser-assisted diamond turning; Lasers; Machinability; MD simulation; Modulus of elasticity; Molecular dynamics; Morphology; Nanoindentation; Numerical analysis; Polycrystals; Subsurface damage; Surface cracks; Surface finish; Temperature effects; Tool life; Tungsten carbide; Turning (machining)
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/j.ijmachtools.2021.103770

The removal mechanism of conventional cutting and in-process-heat laser-assisted cutting (In-LAC) of binderless polycrystalline tungsten carbide (WC) material is studied through systematic numerical analysis and experimental investigation. The proposed In-LAC model considers the accumulated thermal effect and the laser in-process-heat thermal boundary condition simultaneously. Results of molecular dynamics (MD) analysis are remarkably consistent with the experimental results qualitatively. The high-temperature nanoindentation test reveals the improved machinability of WC at an elevated temperature and provides a theoretical basis for cutting force reduction. A small Young's modulus measured at an elevated temperature presents a large elastic recovery value for the In-LAC model. The critical depth of no observed surface cracks of binderless WC increases from 26.6 nm to 106.3 nm, which can be attributed to in-process laser assistance. Furthermore, the In-LAC method is beneficial to avoid subsurface crystal bending and reduce subsurface damage in the MD model and the taper cutting sample subsurface. The existence of the laser annealing effect during the In-LAC process is directly proven by binderless WC cross-section transmission electron microscopy (TEM). According to the simulation analysis results and diamond turning chip morphology, the optimal laser power for polycrystalline WC ranges from 10 W to 15 W, which facilitates obtaining the surface finish of 4.66 nm in Sa and significantly improving the tool life. [Display omitted] •An accurate MD model for In-LAC is successfully established.•The binderless WC removal mechanisms of conventional cutting and In-LAC have been revealed.•The NOSC depth of binderless WC was improved from 26.6 nm to 106.3 nm with better subsurface integrity.•The surface finish of 4.66 nm in Sa was achieved, while the diamond tool wear was improved simultaneously.