Laser Beam Segmentation for Smooth Cut Edge Machining
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Solution Overview
Problem
Laser machining processes often result in unwanted surface irregularities and sharp-edged cut edges, which are difficult to handle and can impair the corrosion resistance and visual appearance of workpieces, necessitating additional post-processing.
Innovation Solution
A machining apparatus and method that splits the laser beam into concentric energy intensity ranges, with a higher energy intensity range for rough machining and a lower range for fine machining, allowing simultaneous or subsequent refinement of cut edges to improve surface finish and reduce post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high energy input is used during rough machining with laser beam, then cutting efficiency is improved, but surface irregularities and unwanted structures are generated on the workpiece surface
Solution Approach 1:
The laser beam is segmented into multiple energy intensity ranges (first range with higher energy for rough machining, second range with lower energy for fine machining). This segmentation allows different portions of the beam to perform different functions: the high-energy core region removes material efficiently while the lower-energy peripheral regions refine the surface, thus resolving the contradiction between cutting efficiency and surface finish quality
Solution Approach 2:
Different energy intensity ranges are applied to different regions of the workpiece surface. The higher energy intensity is concentrated on the cut edge for efficient material removal, while lower energy intensity is applied to adjacent areas for surface refinement. This local differentiation of energy quality enables simultaneous rough and fine machining, resolving the contradiction between productivity and manufacturing precision
2Productivity
If conventional laser cutting method is used, then cutting process is simple and fast, but additional post-processing is required to remove surface irregularities
Solution Approach 1:
The invention merges rough machining and fine machining operations into a single laser cutting process by using multiple energy intensity ranges simultaneously. The first energy intensity range performs rough machining while the second energy intensity range performs fine machining on the same workpiece surface in one pass, eliminating the need for separate post-processing steps and thus resolving the contradiction between cutting speed and ease of manufacture
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 apparatus enables efficient and cost-effective refinement of cut edges during laser machining, enhancing the haptics, machinability, and corrosion resistance of workpieces while optimizing visual appearance without additional processing steps.
Implementation Method 1
the metal material of the workpiece, for example, is burned and vaporised after it has been heated to the ignition temperature by the laser beam
Implementation Method 2
When cutting with an inert gas such as nitrogen or argon, the material of the workpiece is only melted by the laser power
Data Source
AI summary
A machining apparatus for laser machining a work-piece, in particular for laser cutting, is provided, having a device for generating a machining laser beam, for rough machining the work-piece, in particular for producing cuts with cut edges in the workpiece, and having a device for splitting the machining laser beam into at least two energy intensity ranges, wherein a first energy intensity range for rough machining of the workpiece has a greater time-integrated radiation energy than at least one second energy intensity range for at least partially fine machining a cut edge. Further provided is a method a for laser machining a workpiece.