Laser Cut Edge Shaping for Chamfered Holes Without Post-Processing
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Solution Overview
Problem
Current laser cutting processes require extensive mechanical post-processing of cut edges, including rounding and creating countersinks, which is time-consuming and costly, especially for holes, and can result in oxidation issues and loss of galvanization on metal workpieces.
Innovation Solution
A method using a focused processing beam to create troughs and gaps within workpieces, allowing for the direct formation of holes with chamfers, eliminating the need for mechanical post-processing and minimizing oxidation and galvanization loss, by adjusting the beam diameter and focus position to control power density and shape the cut edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional laser cutting with oxygen is used, then cutting speed and automation are improved, but oxidation occurs on cut edges requiring additional grinding and post-processing
Solution Approach 1:
The harmful oxide layer is selectively removed through a second laser pass with different parameters, extracting only the oxidized portion while preserving the base material. This resolves the contradiction by maintaining high-speed oxygen cutting while eliminating the harmful oxidation effect through selective removal.
Solution Approach 2:
The patent applies parameter changes by using two different laser processing modes: first a high-power cutting mode for rapid material separation, then a lower-power remediation mode to remove oxides. This dual-parameter approach enables both high productivity and clean cut edges without oxidation problems.
2Manufacturing precision
If mechanical post-processing is applied to cut edges for rounding and countersinking, then edge quality and fit precision are improved, but production time and labor costs increase significantly
Solution Approach 1:
The patent replaces mechanical post-processing operations with a second laser processing pass that uses controlled melting and vaporization to achieve rounding and countersinking. This substitution eliminates the need for mechanical tools while maintaining edge quality and dramatically reducing processing time.
Solution Approach 2:
The patent merges the cutting operation and edge finishing operation into a single continuous laser processing sequence. By combining these functions that would traditionally require separate machines and operations, the process achieves both high precision edge quality and rapid production without intermediate handling.
3Ease of manufacture
If countersinks are created mechanically for hole fastening, then functional requirements are met, but the process becomes labor-intensive and costly
Solution Approach 1:
The patent replaces complex mechanical countersinking operations with a laser-based melting and vaporization process. The laser selectively removes material in a controlled manner to create the countersink geometry, eliminating the need for specialized mechanical tools and reducing operational complexity.
Solution Approach 2:
The patent uses parameter changes by adjusting laser power, speed, and focus to create different material removal rates that form the countersink shape. This parametric control simplifies the manufacturing process compared to mechanical methods while maintaining ease of operation.
4Reliability
If galvanization is applied to workpieces, then corrosion protection is improved, but the zinc coating is lost around cut edges requiring re-galvanizing
Solution Approach 1:
The patent applies preliminary action by performing the laser remediation process immediately after cutting while the workpiece is still in position. This timely intervention prevents oxidation and protects the galvanization by removing heat-affected zone damage before it can spread, eliminating the need for re-galvanizing.
Solution Approach 2:
The patent converts the harmful thermal effect that damages galvanization into a beneficial controlled melting process. By deliberately using the laser's thermal energy to melt and reshape the edge, the process actually protects the galvanization by creating a clean, oxide-free surface that is more resistant to corrosion.
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
Enables faster, more cost-effective production of workpiece parts with reduced mechanical processing needs and improved surface quality, eliminating the need for complex post-treatment and subsequent galvanization.
Implementation Method 1
a focused processing beam is used to create at least one trough and a gap within the workpiece... the processing beam is a laser beam and the beam processing is laser beam processing
Implementation Method 2
Laser ablation is used to create a trench. During laser ablation, the resulting melt is vaporized
Data Source
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AI summary
The invention relates to a method for the beam machining of a workpiece (9) from which at least one workpiece part (26) is intended to be severed, using a focused machining beam (14), which comprises the following steps of: - creating a hollow (17) in the workpiece (9) using the focused machining beam (14), wherein the hollow (17) is created along at least one portion of a contour (27) of the at least one workpiece part (26) to be severed from the workpiece, - altering a focal position of the machining beam (14) such that the machining beam (14) has a smaller beam diameter on the workpiece (9), - creating a gap (18) in the workpiece (9) using the machining beam (14) with the altered focal position along at least one portion of the contour (27) of the at least one workpiece part (26) to be severed from the workpiece (9), wherein the gap (18) is created at least partially within the hollow (17).