High-power diode laser assisted hard turning of AISI D2 tool steel

Difficulties with the integration of CO2 and Nd-YAG lasers into a machining centre have hitherto impeded industrial implementation of laser assisted machining technologies. The rapidly emerging new technology of high-power diode lasers holds potential in this regard, on account of the laser being compact and the feasibility of fiber optic beam transport. In comparison to other commercial systems, high-power diode lasers combine higher efficiency and metal absorption with lower capital and operating costs; however, their current metal processing applications are confined largely to surface hardening and joining, due to their lower power density. With a view to expanding their application envelope, the work presented in this paper explores high-power diode laser assisted turning of fully hardened AISI D2 tool steel, a material that is difficult to machine. Laser assist is shown to inhibit saw tooth chip formation, suppress chatter, deter catastrophic tool fracture and bring about a substantial reduction in tool wear and cutting forces, with minimal affect on the integrity of the machined surface.