Laser Nozzle Sputter Blocking Jig for Oblique Hole Machining
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Solution Overview
Problem
Laser machining of oblique holes in high-temperature environments, such as combustors, is hindered by sputtering issues that lead to dross deposition, reducing accuracy and increasing processing time, and existing solutions like sacrificial layers complicate the process by requiring additional steps.
Innovation Solution
A laser machining apparatus with a sputter blocking jig and assistive gas system that synchronizes with the laser nozzle to prevent sputtered particles from depositing on the workpiece, using a joint to move both components in tandem and applying the laser beam at an inclined angle to form high-quality oblique holes efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the laser beam is applied at a small angle to elongate oblique holes, then the cooling effect is improved, but the wall thickness increases and processing time increases, resulting in more dross production
Solution Approach 1:
The patent converts the harmful sputtered particles into a beneficial protective layer by allowing them to deposit on the sputter blocking jig instead of the workpiece. The jig acts as a sacrificial element that captures dross, protecting the machined surface and eliminating the need for additional cleaning steps.
Solution Approach 2:
The sputter blocking jig serves as an intermediary element positioned between the laser beam and the workpiece surface. It intercepts sputtered particles and prevents them from contaminating the machined area, thereby maintaining surface quality without affecting the machining parameters.
2Manufacturing precision
If the laser beam is applied at an inclined angle to form oblique cooling holes, then the cooling effect is improved, but sputtering occurs and dross is deposited on the machining surface
Solution Approach 1:
The sputter blocking jig serves as an intermediary element positioned between the laser beam and the workpiece surface. It intercepts sputtered particles and prevents them from contaminating the machined area, thereby maintaining surface quality without affecting the machining parameters.
Solution Approach 2:
The patent extracts the harmful sputtering effect from the workpiece by introducing a separate sputter blocking jig that captures the sputtered particles. This separates the source of the problem (the laser-material interaction) from the victim (the workpiece surface), allowing the machining to proceed without contamination.
3Manufacturing precision
If a sacrificial layer is provided to control tapered shape and prevent burrs, then machining quality is improved, but the number of laser machining steps increases
Solution Approach 1:
The sputter blocking jig serves as an intermediary element positioned between the laser beam and the workpiece surface. It intercepts sputtered particles and prevents them from contaminating the machined area, thereby maintaining surface quality without affecting the machining parameters.
Solution Approach 2:
The sputter blocking jig automatically captures and contains the dross during the machining process itself, eliminating the need for separate post-processing steps. The system serves itself by incorporating the protective function directly into the machining operation.
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 setup minimizes machining failures due to sputtering, reduces processing time, and enables the efficient formation of high-quality oblique holes by effectively blocking sputtered particles and preventing dross deposition, thus improving the laser machining process.
Implementation Method 1
a laser beam is applied to a machining surface of the combustor in order to form oblique holes
Implementation Method 2
applies the laser beam at the set angle with respect to the surface of the workpiece
Implementation Method 3
The laser nozzle supplies an assistive gas to remove undesirable material produced by the applied laser beam
Implementation Method 4
the laser beam is reflected by the machining surface, which tends to cause sputtering. Consequently, molten metal scum (hereinafter referred to as 'dross') frequently is produced by the laser beam
Data Source
AI summary
A laser machining apparatus includes a laser nozzle for supplying an assistive gas to remove undesirable materials and applying a laser beam at an angle, which is inclined with respect to a surface of a workpiece, a sputter blocking jig disposed over a region of the workpiece that is irradiated with the laser beam, so as to lie across directions in which the laser beam is scattered, and for blocking sputtered particles that are generated from the surface by the applied laser beam, and a joint connecting the laser nozzle and the sputter blocking jig to each other. The joint moves the laser nozzle and the sputter blocking jig in synchronism with each other.