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Laser ablation and processing of polycrystalline cubic boron nitride cutting tool material

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Abstract

Laser ablation of polycrystalline cubic boron nitride (PCBN) material has been a great interest to cutting tool design and machining community due to distinct advantages offered by laser surface texturing on flank and rake surfaces of cutting tools for improved friction, reduced tool wear, and enhanced effectiveness of coolant application. There are challenges on controlling the ablation depth and surface integrity induced by laser processing on the PCBN material with CBN grains often with secondary phase as titanium and tungsten carbide, aluminum nitride/aluminum diboride. Surface topography and surface integrity impose effects on the resultant wear and thermal fatigue performance on the cutting tool material. This study investigates the process maps concerning the effect of laser processing parameters on ablation depth of PCBN gathered from several research works on laser ablation and proposes a simulation to predict the laser ablation depth and profile on various CBN content substrates. The results on laser ablation depth are validated against the work in literature as well as experiments conducted using high repetition rate nanosecond laser pulses. Additionally, relations between laser and scanning parameters on the ablation depth have been identified using thermal modeling combined with machine learning, bringing a deeper understanding for texture design and planning of laser surface processing of PCBN.

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Abbreviations

HAZ:

Heat-affected zone

LST:

Laser surface texturing

PCBN:

Polycrystalline cubic boron nitride

PRR:

Pulse repetition rate, 1/s or Hz

SEM:

Scanning electron microscopy

E p :

Laser pulse energy, J

F a :

Areal fluence, J/cm2

F p :

Single pulse fluence, J/cm2

M 2 :

Laser beam quality factor, -

P peak :

Peak laser power, W

P avg :

Average laser power, W

PD :

Distance between laser pulses, mm

PO :

Pulse overlap, μm

Sa:

Arithmetical mean height of the scale-limited surface

Sq:

Root mean square height of the scale-limited surface

Ssk:

Skewness of the scale-limited surface

Sku:

Kurtosis of the scale-limited surface

TD :

Distance between laser tracks, mm

d :

Laser spot size diameter, mm

f :

Pulse frequency, kHz

fs:

Femtosecond, ×10−15 s

l f :

Focal length, mm

ns:

Nanosecond, ×10−9 s

ps:

Picosecond, ×10−12 s

v s :

Scan velocity, mm/min

λ :

Laser wavelength, nm

∆ :

Ablation depth, mm

τ :

Pulse duration, s

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Acknowledgements

The authors are grateful to the resources at University of Basque Country UPV/EHU.

Funding

Funding for this study was partially provided by Taiho Kogyo Tribology Research Foundation (TTRF)

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Authors and Affiliations

  1. Department of Industrial & Systems Engineering, Manufacturing and Automation Research Laboratory, Rutgers University-New Brunswick, Piscataway, New Jersey, USA

    Krzysztof Jarosz & Tuğrul Özel

  2. Department of Mechanical Engineering, University of Basque Country UPV/EHU, Bilbao, Spain

    Eneko Ukar

  3. Institute of Production Engineering and Machine Tools (IFW), Leibniz Universität Hannover, Garbsen, Germany

    Alexander Krödel

Authors
  1. Krzysztof Jarosz
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  2. Eneko Ukar
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  3. Alexander Krödel
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  4. Tuğrul Özel
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Contributions

Conceptualization, K.J., T.Ö.; methodology, K.J.; software, K.J., T.Ö.; validation, S.G. and C.A.B.; formal analysis, A.K., E.U.; investigation, E.U., K.J.; resources, E.U., A.K., K.J., T.Ö.; data curation, E.U., A.K. K.J.; writing—original draft preparation, K.J., T.Ö.; writing—review and editing, K.J., T.Ö., A.K.; visualization, K.J., T.Ö.; supervision, T.Ö.

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Correspondence to Tuğrul Özel.

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Jarosz, K., Ukar, E., Krödel, A. et al. Laser ablation and processing of polycrystalline cubic boron nitride cutting tool material. Int J Adv Manuf Technol 118, 785–800 (2022). https://doi.org/10.1007/s00170-021-07996-2

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