As a novel polishing technology, polishing by laser beam radiation can be used to improve the sample surface finish without causing material losses. In order to study the effect of laser polishing on the surface morphology of S136D die steel, an L₁₆(4⁴) orthogonal experiment was designed to describe the variation trend of surface roughness with energy density. The two-dimensional transient model of laser polishing was established to simulate the evolution process of material surface morphology during laser polishing by combining numerical simulation with the experiment. The model uses a moving laser heat source to study the effects of capillary pressure and thermocapillary pressure in the laser polishing process. The experimental results show that the minimum roughness can be reduced to 0.764 μm, and the error between the actual molten pool depth and the simulated molten pool depth is 5.3%.

Ni60A/WC composite coating is prepared on 45 steel substrate by alternating-magnetic-field-assisted laser cladding. We compare the effects of different magnetic field intensity on WC particle distribution, microstructure, phase composition, microhardness and wear; in addition, the mechanism of alternating magnetic fields on cladding layers is briefly analyzed. The results show that an alternating magnetic field can significantly homogenize the distribution of WC particles. WC particles at the bottom are stirred and dispersed to the middle and upper area of the laser pool. The distribution of WC in the bottom region 6 of the coating decreases from 19.1% to 10%, the distribution of WC in the bottom region 5 decreases from 46.46% to 33.3%, the WC distribution in the top region 1 of the coating increases from 0 to 7.7% and the WC distribution in the top region 2 of the coating increases from 8.08% to 12.2%. The stirring of alternating magnetic fields strengthens the solute convection in the laser pool, refines the snowflake-shaped carbide hard phase and improves the coating microhardness and wear property, and adhesive wear and abrasive wear decrease gradually with increasing magnetic field strength.

As a surface finishing technique for rapid remelting and re-solidification, laser polishing can effectively eliminate the asperities so as to approach the feature size. Nevertheless, the polished surface quality is significantly sensitive to the processing parameters, especially with respect to melt hydrodynamics. In this paper, a transient two-dimensional model was developed to demonstrate the molten flow behavior for different surface morphologies of the Ti6Al4V alloy. It is illustrated that the complex evolution of the melt hydrodynamics involving heat conduction, thermal convection, thermal radiation, melting and solidification during laser polishing. Results show that the uniformity of the distribution of surface peaks and valleys can improve the molten flow stability and obtain better smoothing effect. The high cooling rate of the molten pool resulting in a shortening of the molten lifetime, which prevents the peaks from being removed by capillary and thermocapillary forces. It is revealed that the mechanism of secondary roughness formation on polished surface. Moreover, the double spiral nest Marangoni convection extrudes the molten to the outsides. It results in the formation of expansion and depression, corresponding to nearby the starting position and at the edges of the polished surface. It is further found that the difference between the simulation and experimental depression depths is only about 2 μm. Correspondingly, the errors are approximately 8.3%, 14.3% and 13.3%, corresponding to Models 1, 2 and 3, respectively. The aforementioned results illustrated that the predicted surface profiles agree reasonably well with the experimentally measured surface height data.

A finite element model of the matching of lengthened shrink-fit holder (LSFH) and cutting tool is established and the Rayleigh viscous damping model is used to calculate the reasonable structural damping of this model. A milling force model is developed to predict the transient milling force using back propagation neural network (BPNN). The dynamic characteristic of matching of LSFH and cutting tool is analyzed by means of the universal commercial software ANSYS10.0. The results of numerical simulation are obtained and verified against the practical measurements that show that they are consistent. This study is important to optimum design of LSFH, and to rationally choose the matching of LSFH and cutting tool, deformation analysis, error compensation and parameters optimization in high-speed milling.

Laser polishing is a noncontact and efficient processing method for surface treatment of different materials. It removes surface material and improves its quality by means of a laser beam that acts directly on the surface of the material. The material surface roughness is a major criterion that evaluates the polishing effect when alumina ceramics are polished by a laser. In this study, the effects of three factors, namely, laser power, scanning speed, and pulse frequency, on the surface roughness were investigated through orthogonal tests. The optimum polishing parameters were obtained through a comparison of the experimental results. Compared to the initial surface roughness (Ra = 1.624 μm), the roughness of the polished surface was reduced to Ra = 0.549 μm. A transient two-dimensional model was established by the COMSOL Multiphysics 5.5, and the flow condition of the material inside the molten pool of laser-polished alumina ceramics and the surface morphology of the smoothing process were investigated by utilizing the optimal polishing parameters obtained from the experiments. The simulation results showed that in the process of laser polishing, the fluid inside the molten pool flowed from the peaks to the valleys under the action of capillary force, and the inside of the molten pool tended to be smoothened gradually. In order to verify the correctness of the numerical model, the surface profile at the same position on the material surface was compared, and the results showed that the maximum error between the numerical simulation and the experimental results was 17.8%.