Laser Texture Engraving Patch Layout to Reduce Boundary Marks
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Solution Overview
Problem
Traditional laser ablation methods for engraving workpieces with textures often result in visible markings at the boundaries of adjacent patches, which negatively impacts the quality of the produced parts.
Innovation Solution
The method involves generating multiple machining layers and patches based on the workpiece geometry, with each patch defined by a non-ablation and ablation area. By redefining the position of intersected laser vectors' ends, the number of intersection positions is reduced, minimizing visible markings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional laser ablation method is used to engrave workpiece with texture, then machining efficiency is maintained, but visible markings are generated at patch boundaries reducing part quality
Solution Approach 1:
The patent applies preliminary action by pre-defining optimized patch boundaries and laser vector configurations before the actual machining process. The method calculates and establishes the arrangement of patches and their junctions in advance, ensuring that laser vectors from adjacent patches do not converge at the same boundary points, thereby preventing visible markings before they can occur during machining.
Solution Approach 2:
The patent applies local quality by treating different regions of the workpiece surface with different laser vector strategies. Specifically, the method adjusts the laser vector endpoints and patch junction locations locally at boundary regions to eliminate intersected vectors, while maintaining standard machining parameters in the interior regions of patches.
2Manufacturing precision
If laser path is defined in special way to reduce visible markings, then surface quality improves, but machine time increases and method is not suitable for large continuous areas
Solution Approach 1:
The patent applies segmentation by dividing the workpiece surface into multiple patches with optimized boundaries. This segmentation strategy allows the laser to process each patch independently with pre-calculated vector paths, eliminating the need for complex real-time path adjustments at boundaries while maintaining high surface quality and processing efficiency across large continuous areas.
3Manufacturing precision
If laser beam is led in tracks over surface sections with overlapping regions, then engraving quality improves, but visible marks are still generated at border of neighbouring sections
Solution Approach 1:
The patent applies preliminary action by pre-calculating and optimizing the arrangement of laser vectors and patch boundaries before machining. The method determines in advance which vector endpoints should be positioned at patch junctions and which should be avoided, ensuring that intersected vectors that cause visible marks are eliminated before the machining process begins.
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 approach significantly improves the surface quality by reducing visible markings and enhancing the overall quality of the engraved parts, while maintaining efficient machining processes.
Implementation Method 1
laser ablation method for engraving a workpiece with a texture by a laser beam
Data Source
AI summary
A laser ablation method for engraving a workpiece with a texture by a laser beam emitted by a laser head integrated in a machine tool comprising:a. generating a plurality of machining layers based on the geometry of the workpiece to be machined in succession;b. generating for each machining layer a plurality of patches, each of which defines an area which is to be machined from a single position of the laser head, wherein a first patch and a second patch are positioned adjacent having a common border defined as a patch junction, wherein at least one of the patch includes an non-ablation area and an ablation area based on the texture to be engraved, and the ablation area includes a plurality of laser vectors having two ends defining the path of the laser beam to remove the material of the ablation area, wherein at least one laser vector in the first patch and at least one laser vector in the second patch having a common end at the patch junction are defined as intersected laser vectors and the position of the common end is defined as an intersection position; andc. reducing the number of intersected laser vectors by eliminating at least one intersection position.