Laser Nozzle Positioning at Mach Disk for Melt Blowout
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Solution Overview
Problem
Existing laser processing systems face challenges in effectively blowing out melted material from workpieces using assist gases, often resulting in plasma generation and contamination due to the proximity of the nozzle and workpiece, which affects finishing quality and nozzle integrity.
Innovation Solution
The system optimizes the positioning of the nozzle to align with the maximum velocity points of the assist gas jet, positioning the workpiece within Mach disk regions to enhance gas velocity and prevent plasma generation, utilizing a nozzle with a truncated conical shape and a positioning device to determine the target position based on measured flow rates and velocity profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the nozzle is positioned close to the workpiece to effectively blow out melted material, then the assist gas velocity at the workpiece surface is improved, but plasma generation and nozzle contamination occur due to excessive proximity
Solution Approach 1:
The patent pre-calculates and stores the optimal nozzle position corresponding to the maximum velocity point of the assist gas jet based on flow rate measurements. By retrieving this predetermined position information, the system positions the nozzle at the optimal distance before processing begins, ensuring maximum gas velocity reaches the workpiece without causing plasma generation or contamination.
2Ease of operation
If the nozzle position is fixed at a standard distance, then the system operation is simplified, but the assist gas velocity may not be maximized affecting material removal efficiency
Solution Approach 1:
The patent incorporates a flow rate measurement device that continuously monitors the assist gas flow rate and feeds this information back to the control unit. The control unit uses this feedback to determine the optimal nozzle position corresponding to the maximum velocity point, dynamically adjusting the nozzle position to maintain optimal gas velocity while simplifying operation through automated control.
Solution Approach 2:
The patent changes the operational parameter from a fixed nozzle position to a dynamic position determined by gas flow rate characteristics. By measuring the flow rate and identifying the maximum velocity point, the system adapts the nozzle position parameter to optimize assist gas velocity while preventing harmful effects, balancing operational simplicity with processing effectiveness.
3Productivity
If the nozzle is positioned at the maximum velocity point of the assist gas jet, then material blowout effectiveness is maximized, but precise position determination and control complexity increase
Solution Approach 1:
The patent performs preliminary measurement of the assist gas flow rate characteristics and pre-determines the optimal nozzle position corresponding to the maximum velocity point. This predetermined position information is stored and retrieved during operation, eliminating the need for complex real-time position determination while ensuring maximum material blowout effectiveness.
Solution Approach 2:
The patent creates a predetermined position database that copies and stores the optimal nozzle position information derived from flow rate measurements. During actual processing, the system retrieves this copied position information rather than performing complex real-time calculations, reducing control complexity while maintaining optimal material removal efficiency.
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 configuration ensures effective removal of melted material, improves finishing quality, and reduces nozzle contamination by maximizing assist gas velocity and minimizing plasma generation.
Implementation Method 1
a nozzle including an emission opening configured to emit a jet of an assist gas along an optical axis of a laser beam, the nozzle being configured to form a maximum point of velocity of the jet at a position away from the emission opening
Implementation Method 2
positioning the workpiece within Mach disk regions to enhance gas velocity
Data Source
AI summary
A laser processing system that can effectively blow out a material of a workpiece that is melted by a laser beam by effectively utilizing an assist gas emitted from a nozzle. The laser processing system includes a nozzle including an emission opening configured to emit a jet of an assist gas along an optical axis of a laser beam, the nozzle being configured to form a maximum point of velocity of the jet at a position away from the emission opening; a measuring instrument configured to measure a supply flow rate of the assist gas to the nozzle; and a position acquisition section configured to acquire the position of the maximum point from a measurement value of the measuring instrument by predetermined calculation.