Pulse Beam Irradiation Control for Precise Subtractive Manufacturing
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Solution Overview
Problem
Current processing apparatuses for subtractive manufacturing using energy beams face challenges in accurately determining the optimal irradiation parameters for precise processing of objects, leading to inefficiencies and potential damage due to inadequate control over light penetration depth and processing amounts.
Innovation Solution
A data generation method and cloud system that calculate control data by measuring the shape of a test workpiece, determining light penetration depth, and adjusting irradiation parameters based on object inclination and target processing amounts, ensuring precise control over the processing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If irradiation parameters are not optimized, then processing time can be reduced, but manufacturing precision deteriorates due to inadequate control over light penetration depth and processing amounts
Solution Approach 1:
The system performs preliminary actions by calculating light penetration depth based on object material properties and inclination angle before irradiation begins. Control data is pre-calculated to determine optimal irradiation parameters including number of shots and energy levels, ensuring precise processing without excessive trial-and-error iterations.
Solution Approach 2:
The system implements feedback by measuring the actual shape of the processed object and comparing it with the target shape. Based on this comparison, the system adjusts irradiation parameters for subsequent processing, thereby improving manufacturing precision while maintaining productivity through adaptive optimization.
2Manufacturing precision
If irradiation parameters are not optimized, then energy consumption can be reduced, but manufacturing precision deteriorates due to inadequate control over light penetration depth
Solution Approach 1:
The system calculates the optimal number of shots and energy levels for each irradiation position based on pre-determined light penetration depth. This preliminary calculation ensures that sufficient energy is applied to achieve the desired processing depth without wasting energy on excessive irradiation, thereby improving precision while controlling energy consumption.
Solution Approach 2:
The system applies local quality by adjusting irradiation parameters according to the specific inclination angle and material properties at each irradiation position. This localized optimization ensures that energy is efficiently used to achieve precise processing at each specific location rather than applying uniform high energy across all positions.
3Manufacturing precision
If light penetration depth is not accurately determined, then processing can be simplified, but manufacturing precision deteriorates due to inability to control processing amount
Solution Approach 1:
The system replaces complex mechanical measurement and adjustment mechanisms with computational methods. Light penetration depth is determined through calculations based on object shape data and material properties rather than physical measurement devices, and control data is generated through algorithmic processing rather than manual adjustment, thereby achieving high precision without proportionally increasing device complexity.
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 more accurate and efficient subtractive manufacturing by optimizing irradiation parameters, improving processing precision and reducing material waste, thereby enhancing the overall processing quality and efficiency.
Implementation Method 1
a processing apparatus that is configured to perform a subtractive manufacturing on an object by irradiating a surface of the object with a pulse energy beam
Data Source
AI summary
A data generation method performs subtractive manufacturing by irradiating object with pulse energy beam and measures shape after; calculates information related to light penetration depth into object based on shape information before subtractive manufacturing and measured result of shape after subtractive manufacturing; calculates for each irradiation target position based on information related to an inclination at each irradiation target position of object that is irradiated with pulse energy beam with respect to an irradiation direction of the pulse energy beam and the information related to light penetration depth, a unit processing amount of object in a case where object is irradiated with pulse energy beam a unit number of times; and calculates, based on a target processing amount for each irradiation target position and the unit processing amount for each irradiation target position, a target number of times which each irradiation target position is irradiated with the pulse energy beam.