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Modeling and simulation of ablated profile in laser micro-milling process of Ti6Al4V.

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Title: Modeling and simulation of ablated profile in laser micro-milling process of Ti6Al4V.
Authors: Sahu, Ashish Kumar1,2 (AUTHOR), Jha, Sunil2 (AUTHOR) suniljha@mech.iitd.ac.in
Source: Machining Science & Technology. 2025, Vol. 29 Issue 4, p465-487. 23p.
Subjects: Automotive electronics, Laser beams, Heat equation, Gaussian beams, Depth profiling
Abstract: Laser micromachining is gaining popularity in the current scenario for miniaturizing products with applications in different domains such as biomedical, electronics and automotive. In the present work, the Gaussian profile of the laser beam is used for the simulation of the micromilling of Ti6Al4V alloy, considering a moving heat source. A model has been developed for temperature simulation to understand the thermal interaction of the laser beam with the work material and its melting and vaporization. The temperature model is used to analyze the microgroove depth and width of microgeometry fabricated by laser micro milling. A temperature model consisting of a 3D heat equation is used to analyze the Gaussian laser beam and material interaction phenomena. In the model, the two-stage phase transformation phenomena of solid to liquid and liquid to vapor are considered in the material removal mechanism. The model is solved using a finite element simulation available in COMSOL multiphysics software. A confocal sensor measures the microgroove width and ablation depth of the machined profile. The obtained microgroove width and ablation depth have experimental errors of 16.36% and 26.93% from the simulated results, respectively, which are found to be within an acceptable range. [ABSTRACT FROM AUTHOR]
Copyright of Machining Science & Technology is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Modeling and simulation of ablated profile in laser micro-milling process of Ti6Al4V.
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  Data: <searchLink fieldCode="JN" term="%22Machining+Science+%26+Technology%22">Machining Science & Technology</searchLink>. 2025, Vol. 29 Issue 4, p465-487. 23p.
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  Data: <searchLink fieldCode="DE" term="%22Automotive+electronics%22">Automotive electronics</searchLink><br /><searchLink fieldCode="DE" term="%22Laser+beams%22">Laser beams</searchLink><br /><searchLink fieldCode="DE" term="%22Heat+equation%22">Heat equation</searchLink><br /><searchLink fieldCode="DE" term="%22Gaussian+beams%22">Gaussian beams</searchLink><br /><searchLink fieldCode="DE" term="%22Depth+profiling%22">Depth profiling</searchLink>
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  Label: Abstract
  Group: Ab
  Data: Laser micromachining is gaining popularity in the current scenario for miniaturizing products with applications in different domains such as biomedical, electronics and automotive. In the present work, the Gaussian profile of the laser beam is used for the simulation of the micromilling of Ti6Al4V alloy, considering a moving heat source. A model has been developed for temperature simulation to understand the thermal interaction of the laser beam with the work material and its melting and vaporization. The temperature model is used to analyze the microgroove depth and width of microgeometry fabricated by laser micro milling. A temperature model consisting of a 3D heat equation is used to analyze the Gaussian laser beam and material interaction phenomena. In the model, the two-stage phase transformation phenomena of solid to liquid and liquid to vapor are considered in the material removal mechanism. The model is solved using a finite element simulation available in COMSOL multiphysics software. A confocal sensor measures the microgroove width and ablation depth of the machined profile. The obtained microgroove width and ablation depth have experimental errors of 16.36% and 26.93% from the simulated results, respectively, which are found to be within an acceptable range. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Machining Science & Technology is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1080/10910344.2025.2480779
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      – Code: eng
        Text: English
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        PageCount: 23
        StartPage: 465
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      – SubjectFull: Automotive electronics
        Type: general
      – SubjectFull: Laser beams
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      – SubjectFull: Heat equation
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      – SubjectFull: Gaussian beams
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      – SubjectFull: Depth profiling
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              M: 07
              Text: 2025
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              Y: 2025
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