Virtual Axis Toolpath Planning for Large-Part Laser Texturing
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Solution Overview
Problem
Current laser machining technologies are limited in machining volume due to inefficient utilization of the machine tool's workspace, leading to restrictions on the size of parts that can be machined, especially for large parts requiring 5-axis laser engraving, where the traditional method calculates machining volume without considering the part's geometry and machine stroke, resulting in suboptimal processing.
Innovation Solution
A method for computing a machining toolpath that takes into account the part's geometry, pattern, and machine stroke to optimize the machining volume by recalculating laser head positions and adjusting machining directions within the specified machine stroke, ensuring the laser beam hits the surface at the optimal angle, thereby increasing the maximum part size that can be machined without compromising quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the traditional method calculates machining volume without considering part geometry and machine stroke, then the calculation is simple, but the machining volume is unnecessarily reduced and large parts cannot be machined
Solution Approach 1:
The method performs preliminary simulation of the laser texturing process by obtaining part data defining the geometry of the part and image data defining the pattern to be machined before actual machining. This preliminary simulation calculates the required machining volume based on the specific part geometry and pattern, allowing the system to determine if the part can be machined within the machine's stroke limits before committing to the machining operation.
Solution Approach 2:
The system dynamically adjusts the machining parameters and simulation based on the specific part geometry and machine stroke constraints. By obtaining part positioning data defining the position of the part to be mounted and computing the machining toolpath based on multiple data inputs, the system adapts the toolpath calculation to the specific configuration, maximizing the usable machining volume for each unique part.
2Length of moving object
If the machine tool volume is not optimally used, then the machine structure is simple, but the size of part that can be machined is limited
Solution Approach 1:
The system performs preliminary simulation and calculation of the machining toolpath before actual machining operations. By obtaining part data, image data, machine stroke specifications, and part positioning data in advance, the system can determine the optimal machining approach and identify if the part can be successfully machined within the machine's capabilities, preventing wasted machining operations on parts that cannot be processed.
Solution Approach 2:
The patent replaces traditional mechanical trial-and-error approaches with computer-based simulation and calculation. Instead of physically testing different machining configurations, the system uses computational methods to simulate the laser texturing process and calculate the optimal toolpath, substituting mechanical experimentation with digital modeling to optimize part size utilization.
3Object-affected harmful factors
If chemical etching is used for large parts, then the environmental damage is high, but the process for large parts is established
Solution Approach 1:
The patent replaces chemical etching processes with laser ablation technology. The laser beam is emitted by a laser head installed in a laser machine tool for ablating the material of the part, eliminating the need for chemical substances and their associated environmental hazards while providing a controllable, precise alternative for texturing large parts.
Solution Approach 2:
The system changes the fundamental parameter of the manufacturing process from chemical to optical/thermal energy. By using laser ablation instead of chemical etching, the process transforms from a chemistry-based method to a physics-based method using concentrated light energy to remove material, fundamentally changing how the texturing operation is performed while reducing environmental impact.
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 allows for the machining of larger parts by optimizing the utilization of the machining volume, ensuring high-quality texturing and reducing machining time, while maintaining the environmental benefits of laser texturing over chemical etching.
Implementation Method 1
a laser beam is emitted by a laser head installed in a laser machine tool for ablating the material of a part for forming a pattern thereon
Data Source
AI summary
A method for computing a machining toolpath applied for laser machining process, in which a laser beam is emitted by a laser head installed in a laser machine tool for ablating the material of a part for forming a pattern thereon.