Laser Beam Segmentation for Smooth Laser-Cut Edge Finishing
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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 affect the corrosion resistance and visual appearance of workpieces, necessitating improved surface finish and machinability.
Innovation Solution
A machining apparatus that splits the laser beam into concentric energy intensity ranges, with a higher energy intensity range for rough machining and a lower intensity range for fine machining, allowing simultaneous or sequential refinement of cut edges, and optionally uses a machining gas to optimize the geometry of the cut edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high energy input is used for rough machining with laser beam, then cutting speed and productivity are improved, but surface irregularities and unwanted structures are generated on the cut edge
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 simultaneously, resolving the contradiction between high productivity and surface finish quality by separating the rough cutting and finishing operations into distinct energy zones within a single beam structure.
2Device complexity
If single energy intensity laser beam is used for machining, then device complexity is reduced, but inability to simultaneously achieve rough machining and fine machining increases processing time
Solution Approach 1:
The patent merges rough machining and fine machining capabilities into a single laser beam structure with multiple energy intensity ranges. Instead of using separate lasers or sequential processing, the invention combines different energy zones within one beam, allowing both rough cutting and edge refinement to occur simultaneously, thus reducing total machining time without significantly increasing device complexity.
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 enhances the surface finish and machinability of workpieces by smoothing sharp edges and reducing surface irregularities, improving handling and corrosion resistance, while reducing the need for additional post-processing and increasing efficiency.
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
The reaction between oxygen and the material of the workpiece generates additional heat that supports the cutting process
Implementation Method 3
The melted liquid material, which has a low viscosity, can be removed from the cut edge or from the cutting gap by the shear forces of the gas
Data Source
AI summary
A laser cutting machining apparatus for laser cutting a workpiece includes a device for generating a machining laser beam, for producing cuts with cut edges in the workpiece and for partially fine machining a cut edge, and a device for splitting the machining laser beam into at least two energy intensity ranges. A first energy intensity range for cutting the workpiece has a greater time-integrated radiation energy than a second energy intensity range for fine machining a cut edge. The device for splitting the machining laser beam is configured to adjusts at least one element from a focus diameter of the machining laser beam and/or of at least one of the energy intensity ranges, a focal position of the machining laser beam and/or of at least one of the energy intensity ranges, and a focusing of the machining laser beam and/or of at least one of the energy intensity ranges.