Research on material removal of Ti-6Al-4V by laser-belt machining

Titanium alloys are widely used in aerospace applications due to their exceptional mechanical properties. These materials are difficult to machine and often encounter manufacturing issues such as surface defects and tool wear during conventional machining processes. Laser-assisted machining (LAM) has been proposed as a solution to improve these problems. However, there is a lack of clarity on how to select laser parameters for machining. In this study, a laser temperature field model was established for the laser-assisted grinding (LAG) process. The laser parameters were carefully selected based on the material properties, and subsequent laser-assisted scraping (LAS) experiments were performed. The results indicate that higher laser power leads to improved reduction in cutting force, but it also reduces material removal. The optimal laser parameters determined for this experiment were P = 3.6 W and S = 1000 mm/s. The laser power and scanning speed also influence the morphological characteristics of the chip by affecting the heat flow density on the workpiece surface. When the power exceeds 3.6 W or the scanning speed drops below 200 mm/s, the chip morphology transitions from a saw tooth shape to a folded shape. At laser powers below 4.8 W, the laser primarily heats and softens the chip, resulting in minimal ablation or modification, and the material removal modes remain ductile. During laser-assisted belt grinding, the grinding zone experiences reduced temperature due to the coupling of force and heat.