Liquid-Jet Guided Laser Shaping With Real-Time Ablation Depth Control
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Solution Overview
Problem
Conventional laser-based 3D shaping of workpieces is limited to through-cutting and drilling due to inadequate control over material ablation depth, lacking precise control over z-direction, which restricts the ability to achieve complex 3D shapes efficiently and accurately.
Innovation Solution
An apparatus and method utilizing a laser beam coupled with a fluid jet, where a motion controller sets x-y-z positions and a measuring unit monitors the z-position of the fluid jet's incidence, allowing for precise control over material ablation depth and enabling fast, accurate 3D shaping by adjusting laser energy based on real-time measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser machining is used for workpiece processing, then through-cutting and drilling can be achieved, but precise control over material ablation depth in z-direction is lost
Solution Approach 1:
The patent implements a feedback mechanism by introducing a measuring unit that detects the z-position of the workpiece surface or ablation depth in real-time. This measured information is fed back to the control unit, which adjusts laser parameters (power, pulse duration, frequency) to maintain precise control over material ablation depth. This closed-loop feedback system resolves the information loss about z-position during laser machining.
Solution Approach 2:
The patent employs preliminary action by using the measuring unit to detect the current z-position of the workpiece surface before the laser beam performs material ablation. Based on this pre-measured information, the control unit pre-adjusts the laser parameters to ensure the desired ablation depth is achieved, preventing loss of z-position control before it occurs.
2Productivity
If conventional laser subtractive manufacturing is used, then material can be removed from workpiece, but the process speed is slow and precision is limited
Solution Approach 1:
The patent applies dynamics by making the laser parameters dynamic rather than static. The control unit continuously adjusts laser power, pulse duration, and frequency based on real-time feedback from the measuring unit about the workpiece surface position and ablation depth. This dynamic adaptation allows the system to maintain high precision while operating at optimized speeds, resolving the trade-off between productivity and manufacturing precision.
Solution Approach 2:
The patent utilizes parameter changes by systematically varying laser parameters (power, pulse duration, frequency) based on the measured z-position and desired ablation depth. The control unit modifies these parameters in real-time to optimize both the speed of material removal and the precision of the final shape, thereby improving productivity without sacrificing manufacturing precision.
3Adaptability or versatility
If conventional laser machining apparatus is used, then simple cutting and drilling operations can be performed, but full 3D shaping capability is lacking
Solution Approach 1:
The patent achieves universality by designing a laser machining apparatus that can perform multiple functions: simple cutting, drilling, and complex 3D shaping. The key enabler is the measuring unit combined with the control unit that provides z-position information and adjusts laser parameters accordingly. This multi-functional capability allows the same apparatus to handle diverse machining tasks with precise 3D control, resolving the limitation of conventional apparatus that could only perform simple operations.
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
Enables precise and efficient 3D shaping with the ability to control material removal in all three dimensions, improving the speed and accuracy of the laser-based subtractive manufacturing process, allowing for the creation of complex shapes with high precision and speed.
Implementation Method 1
The present invention relates to an apparatus for three-dimensional (3D) shaping of a workpiece into a final part by material ablation. The material ablation is effected with a laser beam
Implementation Method 2
a laser beam, preferably a pulsed laser beam, which is guided in a fluid jet onto the workpiece
Data Source
AI summary
The invention relates to an apparatus 100 for 3D shaping of a workpiece 101 by material ablation with a laser beam 102. The apparatus 100 comprises a machining unit 103, which is configured to provide a pressurized fluid jet 104 onto the workpiece 101 and to couple the laser beam 102 into the fluid jet 104 towards the workpiece 101. Further, the apparatus 100 includes a motion controller 105 configured to set an x-y-z-position of the workpiece 101 relative to the machining unit 103. It also includes a measuring unit 107 configured to measure a z-position of the point of incidence 108 of the pressurized fluid jet 104 on the workpiece 101 in the z-direction.