Fiber-Oriented Laser Scanning for Uniform Composite Cut Surfaces
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Solution Overview
Problem
Existing laser processing methods for composite materials with reinforced fibers and resin generate heat-affected regions with significant variations, leading to uneven cut surfaces, increased finishing time and costs, and quality variations.
Innovation Solution
A laser processing system and method that calculates and controls the scanning angle and conditions based on the fiber direction and resin properties to minimize heat-affected region variations, using a control device to adjust scanning speed and power of the laser beam accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser beam scanning is performed on composite material, then cutting is achieved, but heat affected region variations cause cut surface unevenness
Solution Approach 1:
The patent applies dynamics by making the scanning conditions adjustable and adaptive rather than fixed. The control device dynamically adjusts scanning parameters (speed, power, waveform) based on real-time feedback from the scanning angle calculation unit, allowing the system to adapt to varying fiber directions and maintain consistent heat affected regions across different material orientations.
Solution Approach 2:
The patent changes physical parameters of the laser scanning process based on scanning angle. The control device modifies scanning speed, laser power, and waveform characteristics according to the calculated scanning angle, thereby compensating for orientation-dependent heat distribution variations and achieving uniform cut surfaces regardless of fiber direction.
2Productivity
If conventional laser scanning is used, then processing is completed, but variations in heat affected region shape and properties generate quality variations
Solution Approach 1:
The patent implements feedback by calculating the scanning angle based on fiber direction and using this information to adjust scanning conditions. The control device continuously monitors and adjusts laser parameters based on the scanning angle feedback, ensuring consistent heat affected region properties and quality across the entire workpiece regardless of orientation variations.
Solution Approach 2:
The patent applies preliminary action by calculating the scanning angle and determining optimal scanning conditions before actual laser processing begins. The control device pre-configures scanning parameters based on the workpiece geometry and fiber orientation, allowing the processing to start with already-optimized conditions that prevent quality variations from the outset.
3Loss of time
If laser processing is performed without angle-based control, then simple processing is achieved, but extra finishing time and costs are required
Solution Approach 1:
The patent applies self-service by enabling the system to automatically calculate scanning angles and adjust its own operating parameters without external intervention. The control device autonomously determines optimal scanning conditions based on embedded workpiece data and fiber orientation information, eliminating the need for manual parameter adjustment and reducing reliance on post-processing finishing operations.
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 system reduces unevenness in cut surfaces by controlling the laser processing conditions, thereby reducing finishing time and costs and improving quality consistency.
Implementation Method 1
a laser processing device that scans a composite material containing a reinforced fiber and a resin with a laser beam to process the composite material
Implementation Method 2
a heat affected region having a length which is approximately a tenth of a processing width by the laser beam is generated starting from the cut surface caused by the laser beam
Data Source
AI summary
A laser processing system and a laser processing method that reduce irregularities on a cutting surface caused by a variation in a heat affected zone or a difference in the heat affected zone due to processing by a laser beam. The laser processing system is provided with: a laser processing device that scans a composite material containing reinforced fibers and a resin with a laser beam to process the composite material; and a control device that controls the laser processing device. The control device calculates a scanning angle formed by a fiber direction that is a direction of the reinforced fibers and a scanning direction that is a direction in which the laser beam is caused to scan, calculates a scanning condition of the laser beam on the basis of the calculated scanning angle, and controls scanning of the laser beam on the basis of the calculated scanning condition.