This project is to develop an economical shaping process for ceramics and other difficult-to-machine materials. The project is to establish the scientific basis for LAM and demonstrate its potential benefits.  The work involves analytical modeling of thermo-mechanical behavior of the material during LAM and experimental investigation of cutting mechanisms and sub-surface
damage.

The potential benefits include a significant reduction in the cost of producing ceramic parts, increased productivity and low initial cost. An experimental system has been constructed by combining a 1.5 KW CO2 laser and a 40 HP CNC lathe. For the optimal design and control of the process, complete thermal and mechanical models of the process is under development as well as in-process temperature measuring systems.

Implementation of LAM with silicon nitride parts resulted in tool life up to 40 minutes, excellent surface finish around 0.4 micron in Ra, little sub-surface damage (within a few microns), no visible cracks and compressive residual stresses.  Other investigated materials include mullite, Zirconia, and metal matrix composites, which all resulted in successful outcome.
 

• Set-up of the Laser Assisted Machining System with a 1.5 KW CO2 laser and a CNC lathe

                    Laser Assisted Machining System
 
• Principle:  Single point tool machining of ceramics

• Modeling Efforts of the LAM Process

1. chip morphology
2. sub-surface damage
3. tool life
4. reduced cutting energy

1.   Material behavior characterization at elevated temperatures.
2.   Thermal property analysis of ceramics.
3.   Thermal modeling of semi-transparent ceramics.
4.   LAM of other difficult-to-machine materials.
5.   Intelligent control of the process.

For further information, visit the lab site.