Laser Contour Machining with Impact Angle Threshold Control
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Solution Overview
Problem
Existing methods for creating contour surfaces on workpieces using laser machining lack precision and efficiency, particularly in achieving high accuracy and maintaining desired geometries during material removal.
Innovation Solution
A method utilizing a laser processing machine with adjustable impact angles for laser beam impulses, ensuring the impact angle is between a minimum and threshold angle to control effective laser energy density, preventing unwanted material removal and maintaining the desired geometry of the contour surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the impact angle of laser beam impulses is increased to improve material removal efficiency, then productivity increases, but manufacturing precision deteriorates due to unwanted material removal and geometry deviations
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the impact angle of laser beam impulses as a critical process parameter. The impact angle is varied within a specific range (0° to 45° relative to the surface normal) depending on the local geometry of the contour surface being created. This parameter optimization enables the system to achieve both high material removal rates and precise contour accuracy by selecting the optimal impact angle for each machining location.
2Productivity
If the impact angle is set to a large value to enhance material removal rate, then productivity improves, but manufacturing precision worsens due to effective laser energy density exceeding threshold fluence and causing unwanted material removal
Solution Approach 1:
The patent implements feedback control by continuously monitoring the impact angle and adjusting it based on the local surface geometry and desired contour. The system calculates the optimal impact angle for each position along the contour path and adjusts the laser beam orientation accordingly. This closed-loop control ensures that the effective laser energy density remains below the threshold fluence for creating new contour surfaces while maintaining high material removal efficiency in volume removal operations.
3Manufacturing precision
If the impact angle is reduced to improve manufacturing precision and prevent unwanted material removal, then manufacturing precision improves, but productivity decreases due to slower material removal
Solution Approach 1:
The patent applies dynamics by making the impact angle a dynamic variable rather than a fixed parameter. The impact angle changes continuously during the machining process based on the local geometry of the workpiece and the specific operation being performed (volume removal vs. contour creation). This dynamic adjustment allows the system to optimize both productivity and precision at different stages and locations of the machining process, rather than being constrained by a single fixed impact angle setting.
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 allows for precise creation of contour surfaces with high accuracy and efficiency by ensuring only necessary material is removed, maintaining the intended geometry and preventing deviations.
Implementation Method 1
A method for material removal laser machining of a workpiece under use of a laser processing machine having a laser creating laser beam impulses
Data Source
AI summary
A method for the material-removing machining of a workpiece by laser beam pulses. The laser beam pulses are directed to impact points on the surface of a volume to be removed of the workpiece in order to cut away material from the volume to be removed. Cutting away the volume to be removed results in a new contour surface to be produced on the workpiece. An impact angle of the laser beam pulses relative to the contour surface to be produced is set in accordance with a predefined condition during the removal of at least part of the volume to be removed that directly adjoins the contour surface to be produced. According to this condition, the impact angle is the same as a threshold angle (as), or somewhat smaller.