In pulsed laser drilling, melt ejection greatly influences the keyhole shape and its quality as well, but its mechanism has not been well understood. In this paper, numerical simulation and experimental investigations...In pulsed laser drilling, melt ejection greatly influences the keyhole shape and its quality as well, but its mechanism has not been well understood. In this paper, numerical simulation and experimental investigations based on 304 stainless steel and aluminum targets are performed to study the effects of material parameters on melt ejection. The numerical method is employed to predict the temperatures, velocity fields in the solid, liquid, and vapour front, and melt pool dynamics of targets as well. The experimental methods include the shadow-graphic technique, weight method, and optical microscope imaging, which are applied to real-time observations of melt ejection phenomena, measurements of collected melt and changes of target mass, observations of surface morphology and the cross-section of the keyhole, respectively. Numerical and experimental results show that the metallic material with high thermal diffusivity like aluminum is prone to have a thick liquid zone and a large quantity of melt ejection. Additionally, to the best of our knowledge, the liquid zone is used to illustrate the relations between melt ejection and material thermal diffusivity for the first time. The research result in this paper is useful for manufacturing optimization and quality control in laser-material interaction.展开更多
Rotation sintering, also known as slush molding, is used to manufacture molded skins, such as dashboards or door interior panels for cars. At present, approximately 80% of such molded skins are manufactured using elec...Rotation sintering, also known as slush molding, is used to manufacture molded skins, such as dashboards or door interior panels for cars. At present, approximately 80% of such molded skins are manufactured using electroforms to achieve the complex free-form surfaces, and surface structures, such as leather graining that the industry demands. The manufacture of these electroforms is, however, time-consuming and expensive. This project aims to replace conventional electroforms with laser-drilled molds. Holes in tool molds should be drilled by using laser radiation as part of an automated process. The system consists of a robot with a fiber-laser beam source. A CAx （computer-aided x） process chain has been developed for this purpose in which the CAD （computer-aided design） data of the tool molds are processed, drill hole fields generated, and a machine-specific RC （robot control） program created. Process-specific fundamentals, such as suitable process windows and process control, have been devised to manufacture holes using fiber laser radiation The advantages of the new laser-drilled tool molds may result in substituting them for conventional electroforms, allowing old markets to be re-entered or additional markets to be created and targeted through new molds or lower costs.展开更多
A theoretical model was developed to describe blind hole profiles in Nd :YAG laser dril- ling. In most cases, the drilled holes resemble a spindle-like shape as is predicted by the theorctical model. Derived from the ...A theoretical model was developed to describe blind hole profiles in Nd :YAG laser dril- ling. In most cases, the drilled holes resemble a spindle-like shape as is predicted by the theorctical model. Derived from the model, an interesting and useful phenomenon: the so-called tunnelling ef- fect, by which cylindrical holes with minimal tapering together with a relatively small heat affected zone can be achieved. The mechanism and the drilling conditions to realize the tunnelling effect are analyzed and experimental evidences are provided.展开更多
Deep microhole machining is currently a prominent research area within the aerospace field,encompassing blade film cooling and fuel injection control technologies.However,taper defects in metal materials may lead to p...Deep microhole machining is currently a prominent research area within the aerospace field,encompassing blade film cooling and fuel injection control technologies.However,taper defects in metal materials may lead to performance degradation or even structural damage over a component’s lifetime.Trepanning and helical drilling,facilitated by ultrashort pulse lasers,have proven more suitable for achieving high-precision,deep holes in metal materials.Nonetheless,excessive repetition rates can also result in severe thermal damage.Various methods are commonly employed for controlling taper,including parameter optimization,assistance,and secondary modification.Tilted laser beam drilling is widely utilized and has been integrated into relevant machining systems for commercial applications.Typical deep microholes include film cooling holes and injection microholes.Laser drilling is a potential machining method for new materials in the aerospace field.Although laser drilling processing has been studied,numerous related scientific challenges and technical difficulties must be addressed before practical implementation.展开更多
Precision drilling with picosecond laser has been advocated to significantly improve the quality of micro-holes with reduced recast layer thickness and almost no heat affected zone.However,a detailed comparison betwee...Precision drilling with picosecond laser has been advocated to significantly improve the quality of micro-holes with reduced recast layer thickness and almost no heat affected zone.However,a detailed comparison between nanosecond and picosecond laser drilling techniques has rarely been reported in previous research.In the present study,a series of micro-holes are manufactured on stainless steel 304 using a nanosecond and a picosecond laser drilling system,respectively.The quality of the micro-holes,e.g.,recast layer,micro-crack,circularity,and conicity,etc,is evaluated by employing an optical microscope,an optical interferometer,and a scanning electron microscope.Additionally,the micro-structure of the samples between the edges of the micro-holes and the parent material is compared following etching treatment.The researching results show that a great amount of spattering material accumulated at the entrance ends of the nanosecond laser drilled micro-holes.The formation of a recast layer with a thickness of;5μm is detected on the side walls,associated with initiation of micro-cracks.Tapering phenomenon is also observed and the circularity of the micro-holes is rather poor.With regard to the micro-holes drilled by picosecond laser,the entrance ends,the exit ends,and the side walls are quite smooth without accumulation of spattering material,formation of recast layer and micro-cracks.The circularity of the micro-holes is fairly good without observation of tapering phenomenon.Furthermore,there is no obvious difference as for the micro-structure between the edges of the micro-holes and the parent material.This study proposes a picosecond laser helical drilling technique which can be used for effective manufacturing of high quality micro-holes.展开更多
A Nd/YAG pulse laser is used to drill Sm Co and Nd Fe B permanent magnetic rotor The experimental studies and analysis on the morphology and the phase composition of the drilled rotor are described In the centr...A Nd/YAG pulse laser is used to drill Sm Co and Nd Fe B permanent magnetic rotor The experimental studies and analysis on the morphology and the phase composition of the drilled rotor are described In the centre of the drilled rotor, there is a hole whose diameter is roughly equal to the girdle size of the Gauss laser beam The hole wall is composed of rapidly fused amorphous matter, whose morphology and composition are obviously different from that before hole drilling The grain in heat affected zone has been fined, but the composition has not changed The experimental results show that the reasonable selection of laser parameters according to physical properties of the materials is necessary in order to improve product quality and production efficiency They also show that the lower laser power, the narrower pulse and the mulitiple drilling are advantageous to the processing for hard brittle materials like rare earth magnets展开更多
The object of this work is to investigate the influence of process parameters on drilling characteristics of an Al 1050 sheet with a thickness of 0.2 mm using a pulsed Nd:YAG laser through numerical analyses and exper...The object of this work is to investigate the influence of process parameters on drilling characteristics of an Al 1050 sheet with a thickness of 0.2 mm using a pulsed Nd:YAG laser through numerical analyses and experiments. By comparing the numerical analyses with the experiments, a proper numerical model was obtained. From the results of the numerical analyses and the experiments, the effects of process parameters on entrance diameters of drilled holes, shapes of the holes, taper angles of the holes and temperature distributions in the vicinity of the holes were examined quantitatively. In addition, the optimal drilling condition was estimated to improve the quality of the drilled holes.展开更多
The aim of this work is to study in detail the drilling process on glass by CO2 laser. The study parameters considered in the present experiments are based on the laser beam power of range (30% - 80% of 25 W) and an e...The aim of this work is to study in detail the drilling process on glass by CO2 laser. The study parameters considered in the present experiments are based on the laser beam power of range (30% - 80% of 25 W) and an exposure time for drilling (2 - 8 s). The measured diameters of holes by optical methods are between [300 - 800 μm]. The results obtained by optical observations suggest that ordinary and mineral glasses cannot withstand to a contact of the laser beam and crack during the formation of the drilling hole. The minimum power and duration of exposure are the optimal parameters for drilling the organic glass, we observe no micro-cracks, and again we see that the edges of the holes have a good surface quality with a high aspect ratio.展开更多
Laser rock spallation is a rock removal process that utilizes laser induced thermal stress to fracture and cause a break through the rock by creating small fragments before melting of the rock. In this paper we invest...Laser rock spallation is a rock removal process that utilizes laser induced thermal stress to fracture and cause a break through the rock by creating small fragments before melting of the rock. In this paper we investigated the effects of CO2 laser irradiation on limestone of Iran Sarvak formation. Since the limestone included heavy and light oil, we studied the amount of laser beam absorption by this oils for determining thermal fractured during the laser drilling laboratory process. In order to characterize this limestone spectrophotometry (from UV to NIR), scanning electron microscopy (SEM) have been used.展开更多
The low-stiffness of aircraft skins may results in the differences between aircraft actual parts and their theoretical models,which will consequently affect the accuracy of automatic drilling and riveting in aircraft ...The low-stiffness of aircraft skins may results in the differences between aircraft actual parts and their theoretical models,which will consequently affect the accuracy of automatic drilling and riveting in aircraft assembly.In this paper,a novel approach of hole position correction using laser line scanner(LLS)is proposed to assign a single row of holes on the parts’surfaces.First,we adopt a space circle fitting method and the random sample consensus(RANSAC)to obtain the precise coordinates of center of the datum holes’coordinates.Second,LLS is calibrated by the laser tracker,and the relations between the LLS coordinate system and the tool coordinate system(TCS)can be calculated.Third,the kinematics model of the automatic riveting machine is established based on a two-point referencing strategy proposed in this paper.Thus,the positions of the holes to be drilled can be adjusted.Finally,the experimental results show that in TCS the measurement error of LLS is less than 0.1 mm,and the correction error of the hole position is less than 0.5 mm,which demonstrates the reliability of our method.展开更多
基金Project supported by the Natural Science Foundation of Jiangsu Province,China(Grant No.KYLX 0341)the National Natural Science Foundation of China(Grant No.61405147)
文摘In pulsed laser drilling, melt ejection greatly influences the keyhole shape and its quality as well, but its mechanism has not been well understood. In this paper, numerical simulation and experimental investigations based on 304 stainless steel and aluminum targets are performed to study the effects of material parameters on melt ejection. The numerical method is employed to predict the temperatures, velocity fields in the solid, liquid, and vapour front, and melt pool dynamics of targets as well. The experimental methods include the shadow-graphic technique, weight method, and optical microscope imaging, which are applied to real-time observations of melt ejection phenomena, measurements of collected melt and changes of target mass, observations of surface morphology and the cross-section of the keyhole, respectively. Numerical and experimental results show that the metallic material with high thermal diffusivity like aluminum is prone to have a thick liquid zone and a large quantity of melt ejection. Additionally, to the best of our knowledge, the liquid zone is used to illustrate the relations between melt ejection and material thermal diffusivity for the first time. The research result in this paper is useful for manufacturing optimization and quality control in laser-material interaction.
文摘Rotation sintering, also known as slush molding, is used to manufacture molded skins, such as dashboards or door interior panels for cars. At present, approximately 80% of such molded skins are manufactured using electroforms to achieve the complex free-form surfaces, and surface structures, such as leather graining that the industry demands. The manufacture of these electroforms is, however, time-consuming and expensive. This project aims to replace conventional electroforms with laser-drilled molds. Holes in tool molds should be drilled by using laser radiation as part of an automated process. The system consists of a robot with a fiber-laser beam source. A CAx （computer-aided x） process chain has been developed for this purpose in which the CAD （computer-aided design） data of the tool molds are processed, drill hole fields generated, and a machine-specific RC （robot control） program created. Process-specific fundamentals, such as suitable process windows and process control, have been devised to manufacture holes using fiber laser radiation The advantages of the new laser-drilled tool molds may result in substituting them for conventional electroforms, allowing old markets to be re-entered or additional markets to be created and targeted through new molds or lower costs.
文摘A theoretical model was developed to describe blind hole profiles in Nd :YAG laser dril- ling. In most cases, the drilled holes resemble a spindle-like shape as is predicted by the theorctical model. Derived from the model, an interesting and useful phenomenon: the so-called tunnelling ef- fect, by which cylindrical holes with minimal tapering together with a relatively small heat affected zone can be achieved. The mechanism and the drilling conditions to realize the tunnelling effect are analyzed and experimental evidences are provided.
基金This work was supported by the Science Center for Gas Turbine Project(Grant No.P2022-A-IV-002-003)the National Natural Science Foundation of China(Grant No.52022078)+1 种基金Shaanxi Provincial Key Research and Development Program(Grant No.2021ZDLGY10-02)the fund of the State Key Laboratory of Solidification Processing in NPU(Grant No.SKLSP202203).
文摘Deep microhole machining is currently a prominent research area within the aerospace field,encompassing blade film cooling and fuel injection control technologies.However,taper defects in metal materials may lead to performance degradation or even structural damage over a component’s lifetime.Trepanning and helical drilling,facilitated by ultrashort pulse lasers,have proven more suitable for achieving high-precision,deep holes in metal materials.Nonetheless,excessive repetition rates can also result in severe thermal damage.Various methods are commonly employed for controlling taper,including parameter optimization,assistance,and secondary modification.Tilted laser beam drilling is widely utilized and has been integrated into relevant machining systems for commercial applications.Typical deep microholes include film cooling holes and injection microholes.Laser drilling is a potential machining method for new materials in the aerospace field.Although laser drilling processing has been studied,numerous related scientific challenges and technical difficulties must be addressed before practical implementation.
基金Supported by National Basic Research Program of China(Grant No.2011CB013004)National Natural Science Foundation of China(Grant No.51005130)Research Fund of State Key Laboratory of Tribology,Tsinghua University(Grant no.SKLT12B06)
文摘Precision drilling with picosecond laser has been advocated to significantly improve the quality of micro-holes with reduced recast layer thickness and almost no heat affected zone.However,a detailed comparison between nanosecond and picosecond laser drilling techniques has rarely been reported in previous research.In the present study,a series of micro-holes are manufactured on stainless steel 304 using a nanosecond and a picosecond laser drilling system,respectively.The quality of the micro-holes,e.g.,recast layer,micro-crack,circularity,and conicity,etc,is evaluated by employing an optical microscope,an optical interferometer,and a scanning electron microscope.Additionally,the micro-structure of the samples between the edges of the micro-holes and the parent material is compared following etching treatment.The researching results show that a great amount of spattering material accumulated at the entrance ends of the nanosecond laser drilled micro-holes.The formation of a recast layer with a thickness of;5μm is detected on the side walls,associated with initiation of micro-cracks.Tapering phenomenon is also observed and the circularity of the micro-holes is rather poor.With regard to the micro-holes drilled by picosecond laser,the entrance ends,the exit ends,and the side walls are quite smooth without accumulation of spattering material,formation of recast layer and micro-cracks.The circularity of the micro-holes is fairly good without observation of tapering phenomenon.Furthermore,there is no obvious difference as for the micro-structure between the edges of the micro-holes and the parent material.This study proposes a picosecond laser helical drilling technique which can be used for effective manufacturing of high quality micro-holes.
文摘A Nd/YAG pulse laser is used to drill Sm Co and Nd Fe B permanent magnetic rotor The experimental studies and analysis on the morphology and the phase composition of the drilled rotor are described In the centre of the drilled rotor, there is a hole whose diameter is roughly equal to the girdle size of the Gauss laser beam The hole wall is composed of rapidly fused amorphous matter, whose morphology and composition are obviously different from that before hole drilling The grain in heat affected zone has been fined, but the composition has not changed The experimental results show that the reasonable selection of laser parameters according to physical properties of the materials is necessary in order to improve product quality and production efficiency They also show that the lower laser power, the narrower pulse and the mulitiple drilling are advantageous to the processing for hard brittle materials like rare earth magnets
基金supported by a grant-in-aid of Regional Innovation Center(RIC),New Technology Development and Research Center of Laser Application in Chosun University,Korea.
文摘The object of this work is to investigate the influence of process parameters on drilling characteristics of an Al 1050 sheet with a thickness of 0.2 mm using a pulsed Nd:YAG laser through numerical analyses and experiments. By comparing the numerical analyses with the experiments, a proper numerical model was obtained. From the results of the numerical analyses and the experiments, the effects of process parameters on entrance diameters of drilled holes, shapes of the holes, taper angles of the holes and temperature distributions in the vicinity of the holes were examined quantitatively. In addition, the optimal drilling condition was estimated to improve the quality of the drilled holes.
文摘The aim of this work is to study in detail the drilling process on glass by CO2 laser. The study parameters considered in the present experiments are based on the laser beam power of range (30% - 80% of 25 W) and an exposure time for drilling (2 - 8 s). The measured diameters of holes by optical methods are between [300 - 800 μm]. The results obtained by optical observations suggest that ordinary and mineral glasses cannot withstand to a contact of the laser beam and crack during the formation of the drilling hole. The minimum power and duration of exposure are the optimal parameters for drilling the organic glass, we observe no micro-cracks, and again we see that the edges of the holes have a good surface quality with a high aspect ratio.
文摘Laser rock spallation is a rock removal process that utilizes laser induced thermal stress to fracture and cause a break through the rock by creating small fragments before melting of the rock. In this paper we investigated the effects of CO2 laser irradiation on limestone of Iran Sarvak formation. Since the limestone included heavy and light oil, we studied the amount of laser beam absorption by this oils for determining thermal fractured during the laser drilling laboratory process. In order to characterize this limestone spectrophotometry (from UV to NIR), scanning electron microscopy (SEM) have been used.
基金supported by the National Natural Science Foundation of China (No.51875287)the National Defense Basic Scientific Research Program of China (No.JCKY2018605C010)the National Key Research and Development Program of China (No.2018YFB1306800)
文摘The low-stiffness of aircraft skins may results in the differences between aircraft actual parts and their theoretical models,which will consequently affect the accuracy of automatic drilling and riveting in aircraft assembly.In this paper,a novel approach of hole position correction using laser line scanner(LLS)is proposed to assign a single row of holes on the parts’surfaces.First,we adopt a space circle fitting method and the random sample consensus(RANSAC)to obtain the precise coordinates of center of the datum holes’coordinates.Second,LLS is calibrated by the laser tracker,and the relations between the LLS coordinate system and the tool coordinate system(TCS)can be calculated.Third,the kinematics model of the automatic riveting machine is established based on a two-point referencing strategy proposed in this paper.Thus,the positions of the holes to be drilled can be adjusted.Finally,the experimental results show that in TCS the measurement error of LLS is less than 0.1 mm,and the correction error of the hole position is less than 0.5 mm,which demonstrates the reliability of our method.
