An experimental study of laser-assisted machining of hard-to-wear white cast iron

Laser-assisted machining has been considered as an alternative for hard-to-wear materials such as metallic alloys and ceramics. Machining of some materials such as high chromium alloys and high strength steels is still a delicate and challenging task and has received little attention. Conventional computer numerical control machines and cutting tools cannot adapt easily to such materials and induce very high tooling costs for operations of rough machining or finishing. This paper presents the results of research conducted on laser-assisted machining of one such hard-to-wear materials, high chromium white cast iron, used in making heavy duty mineral processing equipment for the mining industry. In particular, the effect of laser on temperature, cutting forces, surface profile, hardness and cutting chips are presented. Results show that laser-assisted machining causes more frequent shearing of material, less uniform surface formation, and the heat penetration increases as the distance between laser spot and tool increases. It also leads to reduction in cutting forces with expected improvement in tool life. The results indicate that laser-assisted machining of high chromium white cast iron shows potential to be a feasible alternative to hard machining of such materials. (C) 2011 Elsevier Ltd. All rights reserved.