Thermally enhanced machining of hard-to-machine materials—A review

• Published in: International journal of machine tools & manufacture Vol. 50; no. 8; pp. 663 - 680
• Main Authors: Sun, S., Brandt, M., Dargusch, M.S.
• Format: Journal Article
• Language: English
• Published: Kidlington Elsevier Ltd 01.08.2010; Elsevier
• Subjects: Applied sciences; Cutting force; Cutting tool materials; Cutting tools; Exact sciences and technology; Fundamental areas of phenomenology (including applications); Heat source; Heat sources; Inelasticity (thermoplasticity, viscoplasticity...); Machinability; Machining; Material removal temperature; Mechanical engineering. Machine design; Physics; Solid mechanics; Structural and continuum mechanics; Thermally enhanced machining; Tool wear; Workpieces; Yield strength; Machinability; Heat source; Material removal temperature; Thermally enhanced machining; Tool wear; Cutting force; Work hardening; Tool material; Metal matrix composite; Machining; Metal; Cutting tool materials; Hard material; Inelasticity; Plastic limit; Plasticity; Cutting tool; Shear band; Ceramic materials; Strain hardening
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/j.ijmachtools.2010.04.008

Thermally enhanced machining uses external heat sources to heat and soften the workpiece locally in front of the cutting tool. The temperature rise at the shear zone reduces the yield strength and work hardening of the workpiece, which make the plastic deformation of hard-to-machine materials easier during machining. This review summarizes the up-to-date progress and benefits of thermally enhanced machining (with a focus on laser and plasma assistance) of ceramics, metals and metal matrix composites. It covers the integration of the external heat source with cutting tools, analysis of temperature distribution around the cutting region, material removal mechanisms, tool wear mechanisms and the improvement in machinability of various engineering materials by the assistance of external heat source.