3D Laser Scan Path Planning for Boundary-Consistent Machining
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Solution Overview
Problem
Existing three-dimensional laser beam machining techniques experience non-negligible differences in machining quality between the central and peripheral areas due to discontinuous scanning, leading to potential degradation at boundary portions.
Innovation Solution
A three-dimensional laser beam machining apparatus and method that involves a laser scanning head and stage configured for relative movement, with a machining program controlling laser beam irradiation and movement. The program includes instructions for a sequence of irradiation areas defined by dividing layers in a thickness direction with offset division lines, ensuring continuous scanning across layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the machining target area is divided into a plurality of areas and laser beam scanning is executed for each divided area, then the machining area can be covered completely, but machining quality deteriorates at the boundary portions between adjoining areas due to discontinuous scanning
Solution Approach 1:
The machining target area is divided into a plurality of scanning areas, and the scanning process is segmented into multiple passes. Each pass scans a subset of these areas, and by strategically planning the sequence and overlap of scans across different passes, the system ensures complete coverage while maintaining continuous scanning action within each pass to prevent quality deterioration at boundaries.
Solution Approach 2:
The invention maintains continuous laser beam scanning action within each scanning pass by eliminating unnecessary movements or interruptions. The scanning process proceeds without stopping or resetting within a pass, ensuring that the laser beam continuously processes the material. This continuity is achieved by carefully planning the scan path to cover multiple divided areas in sequence without breaking the scanning flow, thereby preventing quality degradation at boundary portions between areas.
2Ease of operation
If laser beam scanning is executed discontinuously for each divided area, then the machining process can be controlled systematically, but machining quality decreases due to the discontinuous scanning action
Solution Approach 1:
The machining process is segmented into multiple passes, where each pass systematically processes a specific set of scanning areas. This segmentation allows for organized control of the machining operation while maintaining continuous scanning within each pass. The systematic control is achieved by planning which areas to scan in each pass and optimizing the scan sequence, rather than scanning areas in isolation with interruptions.
Solution Approach 2:
The scanning sequence and path are pre-planned and optimized before the actual machining begins. The system determines the optimal arrangement of scanning areas and the sequence of passes in advance, ensuring that continuous scanning can be maintained within each pass. This preliminary planning enables systematic control of the entire machining process while avoiding discontinuous scanning actions that would degrade quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach suppresses machining quality deterioration, improving overall machining precision and efficiency by minimizing quality degradation at boundaries and reducing lead time.
Implementation Method 1
a laser scanning head, configured to remove a part of a workpiece by scanning a surface of the workpiece with a laser beam
Data Source
AI summary
A three-dimensional laser beam machining apparatus includes a laser scanning head and a stage configured to be relatively movable with respect to each other, and a controller configured to control the laser scanning head and the stage based on a machining program. The machining program includes instructions regarding an irradiation sequence of the laser beam for a plurality of irradiation areas, each having the predetermined size. The plurality of irradiation areas are areas defined by dividing each of a plurality of layers, obtained by dividing a three-dimensional model of a target shape in a thickness direction, into a predetermined size in a surface direction using division lines. The division lines are offset from each other for each adjacent layer.