Optimization of laser-tool distance and laser power in laser-assisted milling under material softening and surface quality constraints

Laser-assisted milling (LAM) is a hybrid machining process applied to difficult-to-cut materials. The configuration of process parameters such as laser-tool distance and laser power has a vital influence on the process performance of LAM. An optimization strategy for laser-tool distance and laser power is presented in this paper to provide a selection graph of the two parameters in LAM. The optional laser-tool distance and laser power range are calculated with material softening and white layer formation as constraints. LAM experiments are carried out to validate the presented optimization strategy. Experimental analysis results of cutting force and microstructure are consistent with those reflected in the predicted selection graph, which confirms the optimization strategy is effective. Further, the effect of radial cutting depth and feed rate on the minimum and critical laser power is discussed. This work has practical guiding significance for improving the machining efficiency and surface quality in LAM.