Heat Transfer in Thermally Assisted Machining of Difficult-to-Machine Materials

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9802047Incropera & Shin/Purdue UniversityThis work will theoretically and experimentally study the transport phenomena related to the use of intense localized sources of heat to augment conventional machining of difficult-to-machine materials, such as ceramics and superalloys. Thermally assisted machining (TAM) integrating intense laser sources will be applied to materials such as zirconia and titanium alloys. Theoretical treatments of TAM processes will be used to determine the role of pertinent transport phenomena on thermal conditions in proximity to regions of material removal. Models will consider net radiation and convection transfer from the workpiece surface, conduction and radiation emission, absorption and scattering within the workpiece, friction at the tool-chip interface and energy generation due to material removal by plastic deformation. Supporting experiments will be performed to validate the models and to characterize the surface and sub-surface conditions of the machined specimen. The overall objectives of the work are to obtain an improved understanding of the underlying physical mechanisms for TAM processes and to establish a range of suitable operating conditions.