Dual-Nozzle Laser Processing Head for High-Energy Reliable Coupling
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Solution Overview
Problem
Existing water-assisted laser processing systems face challenges in achieving high energy density while maintaining system reliability due to nozzle damage from position drift and impurity particles, limiting their processing ability and depth.
Innovation Solution
A laser processing head with a dual-nozzle design, where the inner diameter of the first nozzle is larger than the second nozzle, allowing for gradual coupling of the laser with a fluid, reducing the risk of damage and increasing energy density, and a method involving a first fluid and a second fluid with different refractive indices to form a high-energy laser fluid jet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the inner diameter of the nozzle is reduced to enhance laser energy density, then the processing ability and depth are improved, but the nozzle becomes more susceptible to damage from position drift and impurity particles
Solution Approach 1:
The single nozzle is divided into two separate nozzles: a first nozzle with a larger inner diameter and a second nozzle with a smaller inner diameter. This segmentation allows the system to benefit from both large-diameter (reliable) and small-diameter (high energy density) characteristics by using them in sequence, thereby resolving the contradiction between energy density and reliability.
Solution Approach 2:
The first nozzle with larger diameter performs preliminary laser-fluid coupling before the laser enters the second nozzle. This preliminary action prepares the laser beam for the subsequent high-energy-density stage while protecting the more vulnerable second nozzle from direct exposure to high-power laser and impurities.
2Manufacturing precision
If a single small-diameter nozzle is used to achieve high energy density, then processing precision is improved, but the system becomes more vulnerable to position drift and particle damage
Solution Approach 1:
The single nozzle is divided into two separate nozzles: a first nozzle with a larger inner diameter and a second nozzle with a smaller inner diameter. This segmentation allows the system to benefit from both large-diameter (reliable) and small-diameter (high energy density) characteristics by using them in sequence, thereby resolving the contradiction between energy density and reliability.
Solution Approach 2:
The first nozzle with larger diameter performs preliminary laser-fluid coupling before the laser enters the second nozzle. This preliminary action prepares the laser beam for the subsequent high-energy-density stage while protecting the more vulnerable second nozzle from direct exposure to high-power laser and impurities.
3Length of moving object
If the nozzle inner diameter is reduced to enable deep processing, then processing depth is improved, but the risk of nozzle damage from impurity particles increases
Solution Approach 1:
The single nozzle is divided into two separate nozzles: a first nozzle with a larger inner diameter and a second nozzle with a smaller inner diameter. This segmentation allows the system to benefit from both large-diameter (reliable) and small-diameter (high energy density) characteristics by using them in sequence, thereby resolving the contradiction between energy density and reliability.
Solution Approach 2:
The first nozzle with larger diameter performs preliminary laser-fluid coupling before the laser enters the second nozzle. This preliminary action prepares the laser beam for the subsequent high-energy-density stage while protecting the more vulnerable second nozzle from direct exposure to high-power laser and impurities.
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
The solution enhances system reliability and processing ability, enabling deeper and more precise laser processing with improved energy density, overcoming the limitations of prior art by creating an extremely fine laser fluid jet and increasing processing rate.
Implementation Method 1
the laser is converged into the jewel nozzle; consequently, the pulsed laser is emitted along with the water jet flow with a diameter less than 100 micron, forming natural photoconductive effect in the air
Implementation Method 2
combining the water cooling effect with the laser processing effect
Implementation Method 3
removing the material with laser mainly as well as limiting the thermally affected area through cooling of water flow
Implementation Method 4
the removal mechanism is that melting and sublimation coexit
Implementation Method 5
the removal mechanism is that melting and sublimation coexit
Data Source
AI summary
A laser processing head (100) comprises a first-level nozzle (110) and a second-level nozzle (120) that communicate with each other, wherein the second-level nozzle (120) is arranged downstream of the first-level nozzle (110); an inner diameter of the second-level nozzle (120) gradually decreases in a laser transmission direction, and minimum inner diameter of the first-level nozzle (110) is larger than the inner diameter of a tail end of the second-level nozzle (120). The laser processing head (100) solves the contradiction between high energy density laser and the system reliability through gradual coupling. Also provided are a laser processing system and a laser processing method.