Laser-Assisted Machining Device with Beam Splitting Module
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Solution Overview
Problem
Conventional laser-assisted machining devices face challenges in precisely adjusting the laser beam to match the cutting tool's edge, leading to uneven heating and machining inefficiencies, especially when dealing with ceramic workpieces and multi-tooth cutting tools.
Innovation Solution
A laser-assisted machining device with a beam splitting module that splits the main laser beam into multiple secondary beams, which are directed through exit holes to consistently irradiate processing areas on the workpiece, ensuring constant heat application during machining, even for cutting tools with multiple teeth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single laser beam is used to assist machining, then the device structure is simple, but the laser beam cannot precisely match the cutting tool edge and cannot irradiate multiple processing areas simultaneously
Solution Approach 1:
The single laser beam is segmented into multiple secondary laser beams through the beam splitting module, which includes beam splitters and reflecting units. This allows each secondary beam to be directed at different processing areas corresponding to multiple cutting teeth, enabling simultaneous irradiation of multiple zones without requiring multiple independent laser sources.
Solution Approach 2:
The beam splitting module acts as an intermediary between the single laser source and multiple processing areas. It uses optical elements (beam splitters and reflecting units) to redirect and distribute the laser energy to multiple locations, solving the problem of how one laser beam can assist multiple cutting teeth simultaneously.
2Manufacturing precision
If the laser beam is positioned away from the cutting tool edge, then the device structure is simple, but the heating is uneven and causes machining inconsistencies
Solution Approach 1:
The system uses dynamic alignment where the beam splitting module and reflecting units are positioned to move with the spindle rotation. This ensures that the secondary laser beams continuously track and irradiate the processing areas at the cutting tool edge throughout the rotation, maintaining precise heating uniformity without requiring complex external alignment mechanisms.
Solution Approach 2:
The patent transitions from a static single-beam approach to a dynamic multi-dimensional beam distribution system. The laser beams are distributed in multiple spatial dimensions corresponding to different cutting teeth positions, and the system maintains precision by synchronizing beam distribution with spindle rotation in the temporal dimension.
3Productivity
If the laser beam irradiates only one area at a time, then the beam path is simple, but the machining efficiency is low when using multi-tooth cutting tools
Solution Approach 1:
The laser beam is segmented into multiple secondary beams that simultaneously irradiate multiple processing areas corresponding to different cutting teeth. This allows all cutting teeth to benefit from laser-assisted machining at the same time, dramatically improving productivity compared to sequential single-area irradiation.
Solution Approach 2:
The patent merges the functions of multiple independent laser sources into a single laser source with a beam splitting module. This combination achieves the same effect as multiple lasers (simultaneous multi-area irradiation) while maintaining the simplicity of a single laser source, thus improving productivity without proportionally increasing system 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
This design ensures consistent heating and reduced resistance for cutting tools, allowing for efficient machining by maintaining constant irradiation on processing areas, thereby improving the machining process and tool effectiveness.
Implementation Method 1
The beam splitter is disposed in the channel for splitting the main laser beam into a plurality of secondary laser beams that are directed into the chamber
Implementation Method 2
The outer reflecting unit is mounted in the chamber for reflecting the secondary laser beams out of the spindle through the exit holes
Implementation Method 3
The secondary laser beams travel respectively through the exit holes to irradiate respectively a plurality of processing areas on the workpiece
Implementation Method 4
A zone (A) of the ceramic workpiece 13 is heated due to irradiation by the laser beam
Data Source
AI summary
A laser-assisted machining device includes a spindle, a beam splitting module and a cutting tool. The spindle has a chamber, and multiple exit holes. The beam splitting module is disposed in the spindle and includes a beam splitter for splitting a main laser beam into a plurality of secondary laser beams that are directed into the chamber, and an outer reflecting unit mounted in the chamber for reflecting the secondary laser beams out of the spindle through the exit holes. The cutting tool is fixedly mounted on the spindle, for machining a workpiece, and includes multiple cutting teeth. The secondary laser beams maintain constant irradiation on multiple areas of the workpiece during rotation of the spindle.