Laser Nozzle Cross-Flow Gas Suction for Precision Drilling
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Solution Overview
Problem
Conventional laser drilling methods face issues such as enlarged hole diameters due to assist gas deformation, prolonged drilling times for thick or high-specific-gravity workpieces, and contamination of the optical system by splashed melted material.
Innovation Solution
A laser machine with a nozzle design that generates negative pressure by crossing gas flow across the laser beam, using a nozzle with a charge port diameter equal to or larger than the laser beam diameter, an exhaust port with a larger diameter, and a decompressor to create suction, preventing contamination and efficient removal of melted material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If assist gas is blown coaxially with the laser beam to remove melted material and accelerate combustion, then productivity is improved, but manufacturing precision deteriorates due to thermal conduction deforming the workpiece and enlarging the hole diameter
Solution Approach 1:
The gas flow path is segmented into multiple regions: a charge port for gas introduction, a crossing region where gas flows perpendicular to the laser beam, and an exhaust port for removing melted material. This segmentation allows the gas to perform multiple functions (cooling, removing molten material, preventing dross) without causing thermal deformation, thereby resolving the contradiction between productivity and precision
Solution Approach 2:
The gas flow direction is changed from the conventional axial direction (parallel to laser beam) to a crossing direction (perpendicular to laser beam). This dimensional change allows the gas to effectively remove melted material and prevent dross formation without causing thermal conduction deformation, thus improving both productivity and manufacturing precision simultaneously
2Adaptability or versatility
If conventional laser drilling is used on thick or high-specific-gravity workpieces, then the process can be applied to various materials, but productivity deteriorates due to prolonged drilling time
Solution Approach 1:
Gas is supplied in advance through the charge port to create a protective atmosphere and prepare the drilling environment before the laser beam contacts the workpiece. This preliminary gas supply prevents oxidation and prepares for efficient melted material removal, enabling faster drilling of thick and high-specific-gravity materials while maintaining material compatibility
Solution Approach 2:
A pneumatic system is introduced with a gas supply device connected to the charge port, creating a controlled gas flow that assists the laser drilling process. The gas flow effectively removes melted material from the drilling zone, significantly reducing drilling time for thick and high-specific-gravity workpieces while maintaining versatility across different materials
3Productivity
If high power laser is used to drill quickly, then productivity is improved, but object-generated harmful factors worsen due to melted material splashing and contaminating the optical system
Solution Approach 1:
The harmful melted material is extracted from the optical system path by introducing gas flow through the charge port. The gas creates a flow that directs melted material away from the optical components and toward the exhaust port, effectively removing the contamination source while allowing high-power laser drilling to proceed at high speed
Solution Approach 2:
Gas acts as an intermediary substance between the laser beam and the workpiece, creating a protective flow that prevents melted material from reaching the optical system. This intermediary gas flow enables high-power laser drilling without contamination, resolving the contradiction between productivity and optical system protection
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 precise drilling of small holes in workpieces, reduces drilling time for thick materials, and prevents optical system contamination by effectively removing melted material through suction, maintaining the integrity of the laser beam path.
Implementation Method 1
supply gas to the inside of the nozzle tip body along a gas flow path extending from the charge port to the exhaust port in a form of crossing across the laser beam in the nozzle tip body
Implementation Method 2
generate a negative pressure in the vicinity of an opening part of a tip end of the nozzle tip body
Implementation Method 3
cause a melted material to apply a suction force of the weight of the melted material or more. This melted material is sucked from the opening part
Data Source
AI summary
To provide a laser machine capable of reliably drilling a small hole when drilling of the workpiece is performed. A laser machine 1 includes: a laser oscillator; a light guide path; a processing head; and a nozzle. The nozzle includes: a nozzle tip body that irradiates the workpiece with the laser beam; a charge port formed in the nozzle tip body; and an exhaust port formed in the nozzle tip body so as to oppose to the charge port. The nozzle supplies gas to the inside of the nozzle tip body along a gas flow path extending from the charge port to the exhaust port in a form of crossing across the laser beam in the nozzle tip body, to generate a negative pressure in the vicinity of an opening part of a tip end of the nozzle tip body.