Laser-Started Flow Drilling for Low-Force Precision Boreholes
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Solution Overview
Problem
Existing methods for introducing precise boreholes into rod-shaped and plate-shaped workpieces face challenges with high axial forces and burr formation during machining, particularly when using spiral drills or flow drills.
Innovation Solution
A method involving a laser beam to create a recess in the workpiece, which is then widened to the final borehole dimension using a flow drill, reducing axial forces and minimizing burr formation, with optional thread cutting or shaping, and adjustable recess contours for improved precision and reduced tool wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flow drill is used to introduce a borehole directly into the workpiece, then a precise borehole can be produced, but high axial forces are required which increase the supporting force requirement
Solution Approach 1:
A recess is introduced into the workpiece before the flow drilling operation. This preliminary action creates a starting cavity that reduces the material resistance during borehole formation, thereby lowering the axial forces required while maintaining borehole precision
Solution Approach 2:
The borehole creation process is divided into two distinct stages: first creating a recess, then completing the borehole with the flow drill. This segmentation allows each operation to be optimized independently, with the recess preparation reducing the overall force requirement
2Ease of manufacture
If a spiral drill is used to introduce a borehole, then the process is simpler, but chips are produced which complicates the machining process
Solution Approach 1:
The traditional mechanical spiral drilling process is replaced with a laser-based recess creation followed by flow drilling. The laser beam acts as a non-contact tool that removes material without generating chips, eliminating the harmful chip production while maintaining process simplicity
3Productivity
If a borehole is introduced directly without a preliminary recess, then the process is shorter, but burr formation increases requiring additional machining removal
Solution Approach 1:
A recess is created as a preliminary step before completing the borehole. This preliminary action prepares the material by creating a cavity with controlled geometry that guides the flow drill, resulting in minimal burr formation that does not require additional machining removal
Solution Approach 2:
The geometry of the recess is specifically designed with certain dimensional parameters (enveloping circle smaller than final borehole dimension) to optimize the subsequent flow drilling operation, controlling material flow and reducing burr formation
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 enables precise borehole creation with reduced axial forces and minimized burr formation, enhancing positional accuracy and reducing the need for burr removal, while allowing for adjustable recess geometries and thread introduction based on material and workpiece topography.
Implementation Method 1
a laser beam is directed towards a workpiece to be processed via a processing head of a laser processing device
Implementation Method 2
a recess is introduced into the workpiece
Data Source
AI summary
The disclosure relates to systems and methods for machine-cutting workpieces in plate form or bar form and also to a machine tool, with a laser machining device, and a workpiece support, by which a workpiece to be machined in the laser machining device is received, and with a workpiece moving device, by which the workpiece to be machined is held and moved in relation to the laser machining device, wherein with a machining head a laser beam is directed onto the workpiece to be machined and a clearance or recess is introduced into the workpiece and the clearance is machined with a flow drill and widened to a final size of a borehole.