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چکیده
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The increase in thermal loads during the machining process diminishes the surface quality of the component and results in rapid tool wear and early tool replacement. Specifically, the formation of a heat-affected layer induces tensile residual stresses and microstructural alterations. These modifications significantly influence the performance and quality of the final component. Ti6Al4V alloy is a challenging-to-machine material commonly utilized in industries like medicine. With the expansion of industry and the necessity to utilize tough materials across various sectors, the importance of machining hard materials has become more pronounced. Laser-assisted machining is a method through which hard materials can be machined to enhance the machining process and increase the machining rate. The primary objective of this research is to apply a 3D finite element (FE) model of machining Ti6Al4V alloy to forecast the impact of machining parameters on the thermal loads generated during the material removal process and the depth of the affected layer. Initially, the experimental outcomes of the average machined surface temperature during the material removal process were assessed and then compared with the numerical results derived from the 3D simulation process. Insufficient numerical studies have been conducted in existing research to accurately calibrate and quantify heat demands, so using experimental data to refine the model improves accuracy. Furthermore, the maximum temperature produced during the material removal process, which cannot be measured through experimental means, was determined using the 3D FE simulation. Depth of the affected layer by machining was obtained using the critical strain criterion, and the results were compared with corresponding experiments. After that, the influence of process conditions on thermal loads and the depth of the layer that has been affected was investigated and analyzed.
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