Hybrid Manufacturing Process (HMP) Research
The hybrid manufacturing process combines the synergetic effects of Laser and Waterjet to machine brittle materials such as Alumina, Zirconia etc and very hard to machine materials such as Cubic Boron Nitride (CBN), Aluminum Nitride (AlN)etc. The hybrid manufacturing process works on the phenomena of thermal shock fracture. Thermal shock is the process of inducing stresses by creating sudden temperature changes on one of the surfaces of the workpiece. While localized laser heating induces compressive stresses (and creates micro-cracks as well), subsequent cooling by waterjet induces tensile stresses which helps propagate the micro-cracks to fracture the workpiece.
Salient Features of the hybrid process:
- Low Power Laser (<200 W for 1mm thick alumina & <500 W for 1.6 mm thick CBN)
- Low Pressure Waterjet (<7 MPa / 900 psi)
- Higher Cutting Speed (30 mm/s (~70 inch/min) for 1mm thick alumina & 5mm/s (~10 inch/min) for 1.6 mm thick CBN)
- Very low kerf width (<0.1 mm for alumina & <0.2mm for CBN)
- No slag, no spatter
- Smoother cut surface (Ra~4.2um for alumina & Ra~5 um for CBN)