Laser cutting is a popular manufacturing process utilized to cut various types of materials economically. The width of laser cut or kerf, quality of the cut edges and the operating cost are affected ...by laser power, cutting speed, assist gas pressure, nozzle diameter and focus point position as well as the work-piece material. In this paper CO
2 laser cutting of stainless steel of medical grade AISI316L has been investigated. Design of experiment (DOE) was implemented by applying Box–Behnken design to develop the experiment lay-out. The aim of this work is to relate the cutting edge quality parameters namely: upper kerf, lower kerf, the ratio between them, cut section roughness and operating cost to the process parameters mentioned above. Then, an overall optimization routine was applied to find out the optimal cutting setting that would enhance the quality or minimize the operating cost. Mathematical models were developed to determine the relationship between the process parameters and the edge quality features. Also, process parameters effects on the quality features have been defined. Finally, the optimal laser cutting conditions have been found at which the highest quality or minimum cost can be achieved.
► Five different parameters have been investigated simultaneously. ► Estimation of the processing cost. ► The investigation of the ratio between the upper and lower kerfs. ► The optimal operating conditions have been defined.
Poly-methyl-methacrylate (PMMA) microchannel based devices are gaining popularity, particularly in medical applications. Experiments were carried out on a PMMA based microchannel profile of thickness ...10 mm through a 100-Watt CO2 laser machine by varying laser power, scanning speed and number of passes of the laser machine. The full factorial design of the experiment was implemented to investigate the microchannel profile, depth and surface roughness of the microchannel. The analytical model was developed to predict the microchannel profile and depth for the prescribed number of laser passes. The developed analytical model has been compared with the experimental investigations and also with the previously developed models available in the literature. Results of the analytical model predicted the fabricated profile with appreciable accuracy. Moreover, the close agreement of the results with the available literature models validates the acceptability of the proposed analytical model. The surface roughness predictive modeling using linear regression, polynomial regression of order 2,3 and 4, exponential Box-Lucas method and sigmoid Boltzmann models have been compared. The statistical analysis of all the models was performed, with the analysis of variance, mean squared error, Root Mean Square Error, mean absolute percentage error and coefficient of determination. Based on the comparative assessment, the best fitted and accurate model obtained was polynomial regression of order 3. Thus, the improved surface roughness generated with the laser machining would be a time and cost technique for the fabrication of microfluidic devices.
•A range of 2D auxetic mechanical metamaterial sheets capable of exhibiting highly negative Poisson's ratio were produced using direct laser cutting.•Almost all perforated architectures show large ...stretchability and retain their large auxetic behaviour over significant strain ranges.•Influence of boundary effects and out-of-plane thickness on the in-plane mechanical properties were also investigated.•Re-entrant-like systems show anomalous boundary effects which result in non-uniform deformation profiles which could potentially make them ideal candidates for future implementation in sensory devices.
The design and production of multifunctional materials possessing tailored mechanical properties and specialized characteristics is a major theme in modern materials science, particularly for implementation in high-end applications in the biomedical and electronics industry. In this work, a number of metamaterials with perforated architectures possessing the ability to exhibit a plethora of 2D auxetic responses with negative Poisson's ratios ranging from quasi-zero to large negative values (lower than −3.5), stiffnesses, stretchability and surface coverage properties were manufactured. These systems were produced through the introduction of microstructural cuts in a rubber sheet using direct laser cutting, and analysed using a dual approach involving experimental tests and Finite Element Analysis. In addition to examining the mechanical properties of the perforated metamaterials, the influence of edge effects and material thickness on the deformation behaviour of these systems were investigated, with re-entrant systems shown to possess anomalous deformation profiles which are heavily dominated by the boundary regions. These findings highlight the effectiveness of this method for the fabrication of auxetic metamaterial sheets as well as the large variety of mechanical properties, deformation mechanisms and load responses which may be obtained through what may be effectively described as simply the introduction of patterned cuts in a thin sheet.
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•A method of laser cutting thick steel plates without blowing conditions.•The amount and speed of defocusing affect the metal slag discharge.•Off-focus cutting improves cutting and heat distribution ...in thick steel plates.
This study aims to explore the feasibility of defocused laser cutting of thick steel materials without assistant blowing gas, as a basic research on applying laser technology to cut wellhead pipes at long distances at oil and gas drilling rescue sites. The influence of different defocus amounts on the cutting effect was analysed through laser cutting experiments on 20 mm thick 20CrNiMo steel plates under different defocus amounts. In addition, the research developed a novel cutting method, utilising optimised process parameters to achieve efficient cutting of 170 mm thick steel plates without the need for auxiliary blowing gas. The research results reveal the impact of defocus amount on the cutting performance of thick steel and verify the technical feasibility of cutting thick steel without auxiliary gas blowing. This study provides an important reference for defocus cutting technology and its industrial application in unassisted blowing gas laser cutting of thick steel plates.
Silicon is the most widely used material in numerous fields. Traditional mechanical machining methods have been unable to meet the higher requirements of processing quality. Laser machining is ...especially suitable for processing hard and brittle materials due to the non-contact processing characteristics. This article summarizes the nanosecond, picosecond, femtosecond laser drilling and cutting technologies of silicon according to the classification of laser pulse widths. For the most typical field assisted machining technology, liquid-assisted laser drilling and cutting are also discussed. In consideration of the heat generated during laser processing is likely to cause stress in the material, resulting in micro-cracks and other processing defects. Laser induced thermal crack propagation cutting technology (LITP) successfully uses the cracks produced in laser machining to achieve the high cutting quality of silicon. As a new way of material internal processing, laser stealth dicing is the most promising method in the field of wafer cutting. The mechanism and processing characteristics of laser stealth dicing are described. At the end of paper, a summary and outlook are provided.
Herein, we proposed a novel laser assisted additive manufacturing (AM) methodology that utilizes prepreg composites (glass fiber-polypropylene) with continuous fiber reinforcement to fabricate 3D ...objects by implementing laser assisted bonding and laser cutting. The microstructure analysis demonstrated no visible void content and excellent interfacial bonding. The bonding strength of the proposed method was evaluated through lap shear strength and peel strength testing; resulting in 50% higher peel strength than hot compaction method, with lap shear strength up to 96% of compression molding benchmark data. Tensile properties of components printed by our method were superior to those of fused deposition modeling (FDM) printed short fiber composites with 300% and 150% of increase in tensile strength and modulus, respectively. Tensile strength of our printed components was comparable to compression molding and stamping, however, tensile modulus was 50% lower in average. Flexural strength of the laser assisted AM parts was also in the range of stamping and compression molding methods, with flexural modulus up to 100% higher than these methods. Overall, our proposed new technique offers an alternative direction in AM of continuous fiber reinforced thermoplastic polymer composites to solve the issues associated with current techniques.
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•A new laser assisted additive manufacturing (AM) technique was proposed for Continuous fiber reinforced thermoplastic polymer composites (CFRTPCs).•The interfacial bonding was excellent with no visible void content.•Mechanical properties of the 3D objects were comparable with traditional composite manufacturing methods.
In this study, an optimized artificial intelligence model is developed to predict the kerf quality characteristics in laser cutting of basalt fibers reinforced polymer composites. The model is ...composed of Long Short-Term Memory (LSTM) and Chimp Optimization Algorithm (CHOA). The latter is used as an internal optimizer to obtain the optimal parameters of the network model. The developed model was compared with three other models, namely standalone LSTM, LSTM optimized using Heap-Based Optimizer (HBO), and LSTM optimized using Manta Ray Foraging Optimization (MRFO). All models were trained and tested using experimental data considering five process control factors (cutting speed, air pressure, pulse frequency, pulse width and lamp current) and three process response (kerf width, kerf taper and kerf deviation). Response surface methodology was used to design the experimental plan. The accuracy of the models was evaluated and compared to each other using different statistical measures. LSTM-CHOA succeeded to predict kerf quality characteristics of the cut composites despite of their heterogeneous and anisotropic structure and it outperformed the three other models. The root mean squared error of the predicted kerf width, kerf deviation and kerf taper using LSTM-CHOA decreased by about 27.43%, 60% and 56.6%, respectively, compared with that of standalone LSTM.
The object of research in the paper is the technology of manufacturing segments of the rotor rim of large hydrogenerators-motors. The subject of study is the design and geometrical state of the rotor ...rim during the operation of hydraulic units. The goal is to make a three-dimensional mechanical calculation of the rotor segment for the further determination of the most optimal technology for the rotor rim manufacturing. The following tasks are set: to study the peculiarities of the manufacturing technology of the rotor rim segments; to perform an analytical calculation and a three-dimensional calculation with the determination of the average values of stresses and deformations in the rotor segment. The used methods are: finite element method of mathematical modeling of the thermal stress state of nodes. The following results were obtained: a description of the two main manufacturing technologies of the rotor rim segments, namely the stamping method and the laser cutting method, was provided. The advantages and disadvantages of each technological process were analyzed, and it was determined that the laser cutting method should be used in the production of powerful small-scale hydrogenerators. Three-dimensional models of the rotor segment were developed and a three-dimensional mechanical calculation of this model was performed, as a result of which the value of the displacement of the rotor of the hydrogenerator at the nominal frequency of rotation, as well as the average values of the stresses in the spoke and the rim of the rotor, were obtained. Based on the results of calculations, it was established that significant tolerances in the manufacture of rotor segments can lead to changes in the shape of the rotor during its further operation, the appearance of additional vibrations and further affect the performance of the hydraulic unit. The scientific novelty consists in a combined approach to the estimation of the average values of stresses and deformation of the rotor rim, taking into account the technology of its manufacture, which includes elements of analytical mechanical calculation and calculation in a three-dimensional setting.
LASER CUTTING OF SOFT STEEL IN INDUSTRIAL PARTS MANUFACTURING Constantin Cristinel Gîrdu; Mircea Viorel Drăgoi; Mihaela Mileșan ...
Analele Universităţii "Constantin Brâncuşi" din Târgu Jiu: Seria Inginerie,
11/2019, Letnik:
2019, Številka:
2
Journal Article
Recenzirano
Odprti dostop
An interesting study on the cutting of flexible steel using the CO2 laser is discussed in this paper. We used a rigorous mathematical model resulting from the experiments performed to determine the ...cutting speed, the deviation from the circularity of the disks, the geometry of the slit under more efficient conditions. I used a complete plan to make the cut. The focal position influences the cut, respectively the measured sizes. In the measurement process we used for Kerf the scanner and the electronic micrometer, and for the laser-cut surfaces the roughness meter and the durometer. The cutting process has been improved due to the use of the mathematical model. They were highlighted and calculated the cutting speed, the conicity due to the elliptical shape of the cut piece geometry when debiting the piece, conditions for minimizing the slit / cut channel. The relationships resulting from the part geometry indicate the circularity, data for the calculation of errors, the speed of work in stationary and dynamic piercing. The study is complex and varied because it can be supplemented with statistical data processing programs. The results of this article indicate the deviation from the circularity, the ellipse that approximates the piece, the composition of the speeds, the geometric modeling of the piece. All these relationships obtained accurately and accurately reproduce the dimensional accuracy of the pieces. By choosing the formulas expressed we can validate the calculation by comparing the measured values of the output parameters.
Soft steels are used in the processing and fabrication of parts due to corrosion and wear resistance. In the manufacturing technology of these products, a circular cutting experiment was designed ...where disks were obtained at various values of the laser input parameters, cutting speed, gas pressure, laser power, focal position. The present study is based on the circular cutting of the parts made of OL 37 material. The measurements of the discs indicate different and close values from one reference to another, respectively the conicity of the made parts. It is proposed to treat the theoretical aspects related to the stationary and dynamic piercing speed of the laser, the geometry of the piece, the geometric flexibility in determining the deviation from the circularity, the simulation of the addition of melting x depending on the melting angle α, of the geometry of the molten front of the laser leaving from the tip of the laser spot. The method of determining the laser speed in the cutting process is calculated and discussed, the deviation from the circularity, the angle of deviation, the problem of variation of the deviation x from the rectangular dimensional accuracy of the slit due to the laser laser CO2 melting.
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