Laser Head Switching and Angle Control for Cooling Hole Machining
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Solution Overview
Problem
Current laser machining technologies face challenges in consistently machining complex-shaped cooling holes with varying diameters and thicknesses in materials with thermal barrier coatings, leading to issues like dross formation, reduced precision, and increased costs due to the need for multiple laser machines and frequent position changes.
Innovation Solution
A laser machining device with a switch mechanism and irradiation angle change mechanism that uses a single laser machining head to switch between different lasers and adjust angles, allowing for high-quality, high-speed machining of various shapes and sizes without changing the object's position, thereby reducing dross formation and machining time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple laser machines are used to machine both shaped portion and circular hole portion, then machining quality and speed are improved, but device cost and machining time increase due to changeover
Solution Approach 1:
The patent combines two separate laser machines (shaped portion laser machine and circular hole portion laser machine) into a single integrated laser machining device. This device can switch between different laser types (short-pulsed laser for shaped portion, pulsed laser for circular hole portion) and adjust irradiation angles to perform both machining functions, thereby reducing device cost while maintaining machining quality.
Solution Approach 2:
The single laser machining device is designed with multi-functionality to perform both shaped portion machining and circular hole portion machining. It achieves this through a switch mechanism that selects different lasers and an irradiation angle change mechanism that adjusts the laser angle, allowing one device to replace two specialized machines.
2Productivity
If multiple laser machines are used to machine both shaped portion and circular hole portion, then machining quality and speed are improved, but machining time increases due to changeover
Solution Approach 1:
By merging the functionality of two laser machines into one, the patent eliminates the time required for machine changeover. The single device can switch between laser types and adjust angles internally, allowing continuous machining operations without interruption, thus reducing total machining time while maintaining high machining speed.
Solution Approach 2:
The laser machining device performs preliminary setup by pre-configuring the switch mechanism and irradiation angle change mechanism to handle both machining tasks. This preliminary configuration eliminates the need for time-consuming changeover operations during the actual machining process, thereby reducing machining time.
3Manufacturing precision
If laser irradiation angle is changed to machine circular hole portion and shaped portion, then machining quality is improved, but machining time increases due to position changes
Solution Approach 1:
The patent employs an irradiation angle change mechanism that dynamically adjusts the laser irradiation angle during machining operations. This dynamic adjustment allows the device to machine both the shaped portion and circular hole portion with optimal angles without requiring physical repositioning of the workpiece, thereby maintaining high machining precision while reducing machining time.
4Manufacturing precision
If short-pulsed laser is used for shaped portion machining, then machining precision is improved, but machining speed decreases compared to pulsed laser
Solution Approach 1:
The patent changes the laser parameter (pulse width) based on the machining requirements. For the shaped portion, short-pulsed laser with pulse width of 100 microseconds or less is used to achieve high precision. For the circular hole portion, pulsed laser with longer pulse width (sub-milliseconds to milliseconds) is used to achieve high speed machining. The switch mechanism enables parameter changes between different laser types.
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 high-quality, high-precision machining of complex-shaped cooling holes with reduced machining time and cost by using a single laser head to switch between lasers and adjust angles, minimizing dross formation and improving consistency across different materials and shapes.
Implementation Method 1
a condensing optical system configured to condense the laser
Implementation Method 2
the switch mechanism includes a mirror configured to reflect the laser
Data Source
AI summary
A laser machining device includes a laser machining head and a control unit. The laser machining head applies laser for machining an object to be machined, and includes a first laser light source for first laser, a second laser light source for second laser having a different pulse width different from the first laser, a condensing optical system provided between the object and the laser light sources to condense at least the lasers on the object, a switch mechanism provided between the condensing optical system and the laser light sources so that the switch mechanism is movable to a position that at least one of the lasers enters the condensing optical system, and an irradiation angle change mechanism provided between the condensing optical system and the switch mechanism to change an irradiation angle of the first laser. The control unit controls the laser machining head.