Pulsed Laser Cutting of CFRP With Low Resin Thermal Damage
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Solution Overview
Problem
Laser processing of carbon fiber reinforced plastics (CFRP) faces challenges due to thermal conductivity differences between carbon fibers and resin, leading to thermal damage and degradation of mechanical strength during cutting, as the high thermal conductivity of carbon fibers transfers heat to the resin, causing unwanted thermal effects.
Innovation Solution
A laser processing method using pulsed laser light with a pulse width smaller than 1 ms and an energy density capable of forming through-holes by a single pulse, while maintaining an overlap ratio between 0 and 0.5, to minimize thermal impact on the resin and prevent heat-affected zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser output is increased to increase processing speed, then productivity is improved, but thermal damage spreads to resin around processed portion
Solution Approach 1:
The patent applies periodic pulsed laser irradiation instead of continuous laser output. By using pulses with width of 10 ns to 1 ms and controlling the duty cycle, the method delivers high peak power for efficient cutting while allowing cooling intervals that prevent thermal accumulation in the resin, thus resolving the contradiction between processing speed and thermal damage
Solution Approach 2:
The patent dynamically adjusts laser parameters including pulse width (10 ns to 1 ms), repetition frequency (1 Hz to 100 kHz), and duty cycle (1% to 90%) based on material properties and processing requirements. This dynamic control enables optimization of both processing speed and thermal effect management for different composite materials
2Manufacturing precision
If temperature at processing point is adjusted to higher melting point (3500°C) to process carbon fibers, then carbon fibers are effectively processed, but thermal damage spreads to resin with melting point of 250°C
Solution Approach 1:
The patent applies local quality by concentrating laser energy precisely at the processing point through focusing optics, creating a highly localized heat zone. The short pulse duration ensures that only the immediate processing area reaches high temperatures sufficient for carbon fiber processing, while surrounding resin remains below its melting point due to insufficient heat diffusion time
Solution Approach 2:
The patent uses ultra-short pulses (10 ns to 1 ms) to deliver energy so rapidly that the processing occurs before heat can diffuse to surrounding areas. This 'rushing through' approach completes the high-temperature processing of carbon fibers in a time frame too short for thermal damage to propagate to the resin
3Object-affected harmful factors
If through-holes are formed by single pulse to reduce thermal effects, then thermal damage to resin is reduced, but energy density requirements increase
Solution Approach 1:
The patent changes the temporal parameters of laser delivery by using pulse widths from 10 ns to 1 ms with controllable repetition frequencies. This parameter transformation allows the system to achieve high peak power for through-hole penetration while managing total energy input through duty cycle control, thus reducing thermal damage while maintaining effective cutting capability
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 method enables efficient cutting of CFRP with reduced thermal effects on the resin, maintaining mechanical strength and achieving high-quality cuts with improved processing speed and efficiency.
Implementation Method 1
irradiating the workpiece with pulsed laser light from a processing head... forming a plurality of through-holes extending through the workpiece by a single pulse
Data Source
AI summary
A laser processing method for laser processing of a workpiece made of a base material and a fiber reinforced composite material containing fibers having a thermal conductivity and a processing threshold higher than physical properties of glass fibers. The laser processing method includes a step of processing the workpiece by forming a plurality of through-holes extending through the workpiece by irradiating the workpiece with pulsed laser light from a processing head while relatively moving the workpiece and the processing head in a predetermined cutting direction. The pulsed laser light has a pulse width smaller than 1 ms and an energy density capable of forming each of the through-holes by a single pulse.