Laser-assisted Machining (LAM): Modeling and Simulation in Abaqus/CAE

Preview

• What do we learn from this tutorial?
• Teaching plan and prerequisites

Lesson 1: Introduction to Laser-assisted machining (LAM)

• What is conventional machining?
• What is laser heating and laser-assisted machining?
• Laser-assisted machining: A potential approach to machine ‘difficult-to-cut’ materials
• Various approaches to simulate laser-assisted machining

Lesson 2: Building a simple orthogonal machining model in Abaqus/CAE

• Geometry: Cutting tool and workpiece
• Material modeling: Elasto-plastic behaviour, damage initiation, and damage evolution
• Contact modeling: Master and slave surfaces, friction, and heat generation
• Boundary conditions: Speed, feed, and depth of cut definitions. Initial conditions.
• Meshing: Mesh generation, element type, element deletion, and distortion control.
• Analysis of temperature, stress, strain, and cutting forces in machining

Lesson 3: Building a simple laser heating model in Abaqus/CAE

• Introduction to moving heat source and laser heat flux intensity distributions
• Writing DFLUX and VDFLUX subroutines to model moving heat source
• Laser heating parameters: Power, laser-tool gap, scanning speed, and scanning paths
• Insights into 3D heat conduction during laser heating
• Understanding temperature distribution using contour plots and graphs.

Lesson 4: Building a laser-assisted machining model in Abaqus/CAE

• Understanding of all heat sources in LAM: Friction, plastic work, and laser heat flux.
• Integration of laser heating and machining: Revisit to DFLUX/VDFLUX subroutines
• Building both 2D and 3D LAM models
• Parametric analysis of both machining and laser heating process parameters
• Analysis of temperature, stress, strain, and cutting forces in LAM
• Interpretation of simulation results and validation with literature.
• Comparison of results of LAM with simple machining

Discussion on standard results that can be used while writing rese