Off-Axis Liquid Jet Laser Layout to Prevent Nozzle Damage
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Solution Overview
Problem
Prior art laser machining systems with on-axis laser beam delivery face limitations such as nozzle damage from high peak energy, requiring expensive materials and frequent replacements, and trade-offs between energy and frequency, leading to inefficiencies in machining processes.
Innovation Solution
An off-axis liquid jet laser tool design where the laser beam is introduced laterally into the liquid jet stream, utilizing optics and a shielding gas to maintain energy confinement and stability, allowing for higher peak energies and longer nozzle lifespan without damage, and enabling multiple laser beams with varying wavelengths for improved machining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an on-axis laser beam is used in a liquid jet machining system, then the laser energy can be effectively delivered to the workpiece, but the nozzle is damaged by high peak energy requiring expensive materials and frequent replacements
Solution Approach 1:
The laser beam is introduced off-axis (laterally) into the liquid jet stream rather than along the central axis. This dimensional change in beam delivery allows the laser energy to enter the liquid jet from the side, confining the high peak energy interactions to occur away from the nozzle tip, thereby preventing nozzle damage while maintaining effective energy delivery to the workpiece
2Productivity
If high peak energy is used to improve machining speed, then productivity increases, but the nozzle requires expensive materials and frequent replacement
Solution Approach 1:
By introducing the laser beam laterally into the liquid jet stream from a position off the central axis, the system enables high peak energy delivery that improves machining speed while the off-axis entry point ensures that the most intense energy interactions occur within the liquid jet away from the nozzle, allowing use of less expensive nozzle materials
Solution Approach 2:
The harmful effect of high peak energy on the nozzle is extracted or separated from the useful function of energy delivery to the workpiece. The off-axis laser entry allows the liquid jet to carry the high energy beam to the workpiece while the nozzle itself is shielded from the damaging peak energy conditions
3Device complexity
If on-axis laser beam delivery is used, then the system structure is simpler, but the nozzle requires frequent replacements increasing maintenance time
Solution Approach 1:
The off-axis lateral introduction of the laser beam into the liquid jet stream changes the geometric arrangement from a simple on-axis configuration to a side-entry configuration. This dimensional change protects the nozzle from damage, reducing maintenance frequency and downtime, while the added optical components for off-axis beam delivery are offset by the reduced maintenance requirements
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 off-axis design prevents nozzle damage, allows for higher peak and average laser energies, reduces maintenance costs, and enhances machining efficiency with improved energy distribution and processing speed, using less expensive materials and minimizing downtime.
Implementation Method 1
The laser beam then travels through the liquid jet stream undergoing total internal reflection as in an optical waveguide or fiber optic
Data Source
AI summary
Techniques are disclosed for a liquid jet laser tool that employs an off-axis laser beam and a liquid jet stream ejected from a nozzle. The off-axis design allows the beam to be directed into the jet stream from a lateral position at an angle of incidence that causes it to propagate/travel internally within the jet stream. Any requisite optics are employed to direct the laser beam into the jet stream. The laser beam thus confined in the liquid jet stream arrives at a workpiece. The off-axis design prevents the damage to the nozzle by the laser, and thus minimizes/eliminates the need for its replacement thereby increasing efficiency and reducing operational costs. In embodiments, multiple laser beams are directed into the jet stream that simultaneously propagate within the jet stream to arrive at the workpiece. The multi-laser design accrues benefits including more uniform laser energy, higher peak power, reduced maintenance, and the like.