Laser-assisted milling—Process modeling and experimental validation

Due to their advantageous material properties, components made from titanium alloys, such as TiAl6V4, are used predominately in the aerospace industry. However, the cost-effectiveness of machining operations is limited by high production times and costs. Laser-assisted milling represents a method to enhance productivity in comparison to conventional milling. This paper presents a novel processing strategy and a simulation based model of this hybrid process. The developed model is validated by investigating cutting forces and tool wear. The identified material removal rates provide a basis for a cost-analysis. A calculation of a use case showed that laser-assisted milling is an economical alternative to conventional milling.