Adjustable Laser Micromachining for Deep Slot Milling
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Solution Overview
Problem
Conventional micro milling of advanced engineering materials faces challenges such as short tool life, poor machined surface integrity, and limited flexibility in laser-assisted micromachining systems, particularly due to fixed laser beam delivery and high incidence angles, which hinder precise machining of complex features and deep slots.
Innovation Solution
A laser-assisted micromachining system with adjustable optical elements, including a rotatable mirror setup and a 1-axis stage, allows for flexible laser beam positioning and low incidence angles, enabling precise control of the laser spot size and beam path to improve tool life and surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed laser beam delivery system is used, then the system structure is simple, but the flexibility in adjusting laser spot size and beam path is limited
Solution Approach 1:
The patent applies dynamics by making the optical elements (mirrors and lenses) adjustable and reconfigurable. The system includes movable mirrors with adjustable angles and positions, and a variable focus lens that can change focal length, allowing the laser beam path and spot size to be dynamically adjusted according to different machining requirements while maintaining a relatively compact system structure.
2Adaptability or versatility
If a high incidence angle is used in laser-assisted micromachining, then the laser beam can be delivered in limited space, but the machining flexibility for deep slots and contouring is reduced
Solution Approach 1:
The patent uses another dimension by introducing adjustable angular positioning of mirrors in addition to linear movement. The system can vary the incidence angle of the laser beam by rotating mirrors around the workpiece, enabling access to deep slots and complex contours without extending the linear beam path length, thus utilizing angular space to overcome spatial constraints.
3Reliability
If conventional micro milling is used for advanced engineering materials, then the equipment is simple, but the tool life is short and surface integrity is poor
Solution Approach 1:
The patent merges laser heating technology with conventional micro milling to create a hybrid laser-assisted micromachining system. The laser pre-heats the workpiece material before the cutting tool engages, reducing material strength and improving chip formation, thereby extending tool life and enhancing surface integrity while maintaining the relatively simple structure of conventional milling equipment.
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 system achieves high material removal rates and improved machined surface integrity for advanced engineering materials like ceramics and high-temperature alloys, enabling complex feature machining and extending the applicability of laser-assisted micromachining to processes like contouring and deep slot milling.
Implementation Method 1
a laser beam source, optical elements arranged to define a path of a laser beam emitted by the laser beam source
Implementation Method 2
the optical elements include at least a first mirror mounted in fixed relation to the laser beam source, and means for adjustably mounting a second mirror to project the laser beam onto the workpiece
Data Source
AI summary
Laser-assisted micromachining methods and systems capable of providing flexible beam positioning and low incident angles. Such laser-assisted micromachining systems preferably include a laser beam source, a cutting tool, means for engaging a workpiece with the cutting tool, optical elements arranged to define a path of a laser beam emitted by the laser beam source wherein the optical elements include at least a first mirror mounted in fixed relation to the laser beam source, and means for adjustably mounting a second mirror to project the laser beam onto the workpiece in proximity to the cutting tool and at an incidence angle relative to a surface of the workpiece.