MANUFACTURING OF

CERAMIC MACHINE
M.Tech Manufacturing Major Project

CONTENT

Introduction
Highlight of Literature Review
Gaps in the literature and problem definition
Scope of current work
Methodology
Work done
Work in progress
Time schedule

INTRODUCTION

Laser assisted machining is one of the advanced

manufacturing process. Laser assisted machining improves
machining characteristics by reducing the cutting force
finishing the surface roughness and tool wear. Now a days
Ceramics and super alloys are mainly used in aerospace
industries due to their oxidation and corrosion-resistant
property. Inconel is used to make dome, aft shaft, whereas
Ceramics are used to make nose and outer dome in
missiles. Machining of super alloys and ceramics is
expensive due to more machining time and high rate of tool
wear. In order to reduce machining cost we are planning to
use the concept of laser assisted machining process for
machining. Laser technology offers different method of
beam generation with continuous wave or pulsed wave of
m.

HIGHLIGHTS OF
LITERATURE

Paper 1:- Analysis of tool wear patterns in finishing

turning of Inconel 718

Tool wear mechanisms during finishing turning of Inconel 718 have

been analyzed in this paper. Tests were performed with coolant and
also in dry conditions. Commercial inserts were tested and it was
proved the feasibility of dry turning with the tools

Paper 2:- Modeling of machining of composite materials

The paper has provided a literature review on modeling of composite machining
over the last 1015 years with a specific focus on the process of turning.
Tremendous strides have been made in the modeling of composite machining
with methods ranging from considering the composite material as an equivalent
homogenous material to explicitly modeling all the phases of the material.

HIGHLIGHTS OF
LITERATURE
Paper 3:- Investigation into the effect of overlap factors and
process parameters on surface roughness and machined depth
during micro-turning process with Nd:YAG laser

In this paper I have come to know spot overlap and

circumferential overlap factors on laser micro-turning
operation have been done for achieving desired surface
roughness. From where we get the idea of micro machining
of ceramic with the help of laser and spot over lapping
Paper
laser. 4:- Laser machining of structural ceramics.
In this study, an attempt has been made to cover the laser
machining of several structural ceramics such as alumina, silicon
nitride, silicon carbide, aluminum nitride, zirconia and magnesia
after thoroughly understanding the physical phenomena associated
with the machining process.

HIGHLIGHTS OF
LITERATURE

Paper 5:- Pulsed laser-assisted machining of Inconel

superalloy.
In this study of laser assisted machining of Inconel is carried out under
various process parameter using carbide tool. Comparison of conventional
machining of Inconel and Laser-assisted machining is preferred.

PROBLEM DEFINITION

Machining of Inconel or Ceramic with uncoated cemented

carbide tool is limited to a low cutting speed of 60 m/min
due to high mechanical and thermal loads which adversely
affect . To improve the tool life and process efficiency, new
tool materials such as coated carbide tools can be used like
PVD and CVD tools or coated CBN tools. But use of these
tools will slightly increase the production rate of the
company. These tools are suitable for machining superalloys
but to machine ceramics these tool will wear at much
higher rate and material removal rate is also less. To
eliminate or reduce the rate of tool wear, laser assisted
machining process is been adopted.
Later planning to use Taguchi method for analysis of tool
wear and material removal rate for superalloys and
Ceramics.

SCOPE OF CURRENT WORK

Will improve the productivity of the industry

Helps in reduction production cost
Helps in reducing tool change over time
Can make program with long cycle time
Will be able to machine ceramics in much better rate
then by using only coated tool

METHODOLOGY

This project is divided in three different part.

1. Turning of superalloy with a hard submicron substrate,
TiAlN PVD coated grade followed by a special 'SUMO TEC'
surface treatment. Suitable for turning hard nickel base
alloys / Inconel (40-50 HRC) at low to medium cutting
speeds.
Tool supplier ISCAR
Item Code:- CNMG 120408
Material:- Inconel 718.

METHODOLOGY

Property of Inconel 718 material

Ni

Cr

Fe

50.0

55.0

17.0

21.0

balan
ce

M
o
2.8

3.3

Nb

Co

Mn

Cu

Al

Ti

Si

4.75
5.5

1.0

0.35

0.2
0.8

0.65
1.15

0.3

0.35

0.08

0.01
5

0.01
5

0.00
6

Cutting tool Geometry

METHODOLOGY

Turning operation was performed on a high speed precision

lathe by HMT model No. N22, having maximum spindle
speed of 2040rpm feed of .1mm is given per cycle and tool
life is calculated after 10 cycle.
2. In second part of experiment laser is used in HMT
model No. N22, laser head is used to project laser
perpendicular to the work piece, laser head is attached to
this laser arm.

Laser Arm 3-D Model in Siemens Nx 8.5.

METHODOLOGY

Laser specifications
Manufacturer:FANUC
Model No.:FANUC Laser C4000i
Laser type:Nd:YAG laser (pulsed)
Wavelength:1064 nm
Polarization of beam:- Random
Beam average power,(W) 6, 7, 8, 9, 10
Pulse frequency, Hz 3000, 4000, 5000, 6000, 7000

METHODOLOGY

3. In this stage of we are planning to synchronize laser

arm with CNC machine, CTX 410 V3 by GILDEMEISTER,
with the help of stepper motor.

WORK DONE

2 out of 3 part of the project is completed.

WORK IN PROGRESS

First two stages of my project is completed and have

started designing new laser arm for this machine with 3
degree of freedom, and providing position to attach stepper
motor, which will be synchronized with the CNC machine
for precision machining of parts and using certain sensors
like Pyrometer which will help in maintaining the
temperature of the work piece to protect work piece from
over heating.

TIME SCHEDULE

Estimated time to finish the program in next 3 months.