Improved direct laser assisted machining of Al 7075-T6 and Ti-6Al-4V using cubic zirconia tool

Direct laser assisted machining (DLAM) is an effective way to improve the machinability of superalloys. It makes important progress compared to conventional laser assisted machining that enable the heating and cutting simultaneously during machining process. In the present work, improved DLAM based on the cubic zirconia tool is developed. By utilizing the Cubic Zirconia tool, improved DLAM has higher applicability and less cost. For the first time, DLAM cutting tests on Al 7075-T6 and Ti-6Al-4V are performed varying the cutting speeds and laser output powers. Cutting forces, surface roughness, and chip morphology are observed and compared. Finite element simulation is performed to estimate the cutting temperature for all cutting conditions. The study's results suggest that the DLAM with cubic zirconia tool could improve the cutting of alloys by less cutting forces and smoother surface finish. The work provides significant insight into the cutting mechanism of DLAM.