Laser Beam Piercing with Spatter-Root Heating for Coated Workpieces
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Solution Overview
Problem
Existing laser piercing methods face challenges in preventing spatter adherence to the workpiece during the piercing process, leading to reduced machining quality.
Innovation Solution
A laser piercing method that involves spraying oil onto the workpiece, emitting a bundle of laser beams with varying output densities, and using a second laser beam to heat the spatter roots, preventing adherence to the machined workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single laser beam is used for piercing, then the piercing process is simple, but spatter adheres to the workpiece reducing machining quality
Solution Approach 1:
The laser beam is divided into multiple beams (first laser beam for melting, second laser beam for heating spatter roots) to simultaneously achieve piercing and spatter prevention, resolving the contradiction between machining quality and device complexity
Solution Approach 2:
The bundle of laser beams serves multiple functions: the first laser beam performs melting and piercing while the second laser beam prevents spatter adherence, allowing a single laser system to accomplish both tasks that would otherwise require separate processes
2Manufacturing precision
If oil is sprayed to the workpiece, then spatter adherence is reduced, but the piercing process becomes more complex
Solution Approach 1:
Oil is sprayed onto the workpiece before laser piercing to create a coated portion that prevents spatter adherence, addressing the spatter issue before the piercing process begins
Solution Approach 2:
Oil acts as an intermediary substance between the laser beam and the workpiece, facilitating easier spatter removal while the laser beams perform the actual piercing and heating functions
3Productivity
If high laser output density is used, then piercing efficiency is high, but spatter adherence increases
Solution Approach 1:
Different regions of the laser beam bundle have different output densities: the first laser beam maintains high density for efficient piercing while the second laser beam uses lower density to heat spatter roots and prevent adherence, resolving the contradiction between piercing efficiency and spatter control
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 method effectively prevents spatter from adhering to the workpiece, improving machining quality by ensuring easy removal of spatters and maintaining the integrity of the pierced holes.
Implementation Method 1
melting an center portion of the workpiece on which the first laser beam is cast to generate molten material
Implementation Method 2
heating a root of a spatter by a second laser beam, the spatter being the molten material scattered around the center portion
Implementation Method 3
spraying gas to the center portion to scatter the molten material around the center portion
Data Source
AI summary
A laser piercing method includes emitting a bundle of laser beams to the coated portion in a beam direction, the bundle of laser beams comprising: a first laser beam having a first laser output density; and a second laser beam surrounding the first laser beam as viewed in the beam direction and having a second laser output density smaller than the first laser output density. The method includes piercing the coated portion to form a pierced hole by: melting a center portion of the workpiece on which the first laser beam is cast to generate molten material; and spraying gas to the center portion to scatter the molten material around the center portion. The method includes heating a root of a spatter by a second laser beam, the spatter being the molten material scattered, the root contacting a machined workpiece that is the workpiece with the molten material removed.