ABSTRACT

Hard materials such as titanium, Inconel, and nickel alloys are mostly used in aerospace, automobiles, and medical devices. These materials are difficult to machine with conventional machining (CM) methods. Learning new machining methods developed for these materials is essential.

One of these machining methods, Thermal Assisted Machining (TAM), is applicable. A heat source for increasing the machinability of materials, Laser assisted milling (LAMill), is a widely used type of Thermal Assisted Machining.

In the laser assisted milling process, a laser heat source softens the material in front of the cutting tool. Even though laser assisted milling is expensive, plasma heat source is widely used for welding, melting, preheating, etc.

But few studies have been done on plasma assisted machining (PAM). In this study a PAM process was developed investigated and its performance was compared with Laser assisted milling and conventional machining.

The correct preheating temperature and depth of cut (DOC) were determined through thermal analysis. Experiments were performed using the PAM system on used AISI 1045 steel and Inconel 718.

The results of the experiments showed that PAM and LAMill produced excellent effects with respect to tool life and the machined material surface. However, the cost of the plasma heat source is much lower than that of LAMill.