Nanosecond Yb fibre laser milling of aluminium: effect of process parameters on the achievable surface finish and machining efficiency

Williams, Eleri; Brousseau, Emmanuel Bruno Jean Paul; Rees, Andrew

doi:10.1007/s00170-014-6038-6

Cited by 37 publications

(15 citation statements)

References 16 publications

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“…8 High-power Yb 3+ -doped fiber lasers at the wavelength of λ ∼ 1 µm have found extensive applications in metal processing like welding, milling, and marking. 9,10 Extension to the UV would benefit applications such as precise micromachining and processing/marking of insulators, which are usually energy inefficient when carried out with near IR lasers and would benefit from an improved optical absorption, higher resolution as well as minimized thermal damage.…”

confidence: 99%

Ultraviolet photoluminescence in Gd-doped silica and phosphosilicate fibers

Wang

Barua

et al. 2017

APL Photonics

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confidence: 99%

Ultraviolet photoluminescence in Gd-doped silica and phosphosilicate fibers

Wang

Barua

et al. 2017

APL Photonics

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“…For example, as per the results of Dhaker et al [ 36 ], the quality of laser drilled holes in Inconel 718 is not easy to achieve without the absence of optimized parameters. Williams et al [ 37 ] studied the effect of fiber laser parameters during machining of aluminum. Kuar et al [ 38 ] proposed an optimized set of Nd:YAG laser parameters to perform micro-machining of die-steel.…”

Section: Introductionmentioning

confidence: 99%

Achieving the Minimum Roughness of Laser Milled Micro-Impressions on Ti 6Al 4V, Inconel 718, and Duralumin

et al. 2020

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Titanium-aluminium-vanadium (Ti 6Al 4V) alloys, nickel alloys (Inconel 718), and duraluminum alloys (AA 2000 series) are widely used materials in numerous engineering applications wherein machined features are required to having good surface finish. In this research, micro-impressions of 12 µm depth are milled on these materials though laser milling. Response surface methodology based design of experiment is followed resulting in 54 experiments per work material. Five laser parameters are considered naming lamp current intensity (I), pulse frequency (f), scanning speed (V), layer thickness (LT), and track displacement (TD). Process performance is evaluated and compared in terms of surface roughness through several statistical and microscopic analysis. The significance, strength, and direction of each of the five laser parametric effects are deeply investigated for the said alloys. Optimized laser parameters are proposed to achieve minimum surface roughness. For the optimized combination of laser parameters to achieve minimum surface roughness (Ra) in the titanium alloy, the said alloy consists of I = 85%, f = 20 kHz, V = 250 mm/s, TD = 11 µm, and LT = 3 µm. Similarly, optimized parameters for nickel alloy are as follows: I = 85%, f = 20 kHz, V = 256 mm/s, TD = 8 µm, and LT = 1 µm. Minimum roughness (Ra) on the surface of aluminum alloys can be achieved under the following optimized parameters: I = 75%, f = 20 kHz, V = 200 mm/s, TD = 12 µm, and LT = 3 µm. Micro-impressions produced under optimized parameters have surface roughness of 0.56 µm, 2.46 µm, and 0.54 µm on titanium alloy, nickel alloy, and duralumin, respectively. Some engineering applications need to have high surface roughness (e.g., in case of biomedical implants) or some desired level of roughness. Therefore, validated statistical models are presented to estimate the desired level of roughness against any laser parametric settings.

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“…However, the manufacture of the moulding tools that incorporate micro and nano features and enhance the replication fidelity (RF) at all scales remains a key enabling component of the process chain [3]. Micro moulding tools are manufactured through the innovative combination of complementary micro/nano machining and structuring technologies such as micro electrical discharge machining (μEDM), laser ablation, micro milling and focused ion beam machining [5,6,7,8,9]. The demand for micro/nano length scale integration features within injection moulding tools results in cavities being produced with technologies that combine so called top-down structuring with bottom-up technologies.…”

Section: Introductionmentioning

confidence: 99%

Temperature effects on DLC coated micro moulds

Griffiths

Rees

Kerton

et al. 2016

Surface and Coatings Technology

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Microinjection moulding is a key enabling technology for replicating miniaturized components and parts with functional features at the micrometer and even submicrometer length scale. The micro moulding tools used in the process chain are critical for delivering high quality parts for the duration of the product life cycle, and recently tool coatings such as Diamond-like carbon (DLC) have been used to extend their use and enhance the performance. The micro injection moulding process has high injection speeds with cyclic heat transfer characteristics, and little is understood on how the localised heat transfer at the surface will influence the DLC surface coating delamination and cracking. In this research a microinjection moulding process using three different polymers, Polypropylene (PP), Acrylonitrile butadiene styrene (ABS) and Polyether ether ketone (PEEK) is studied. Finite element analysis (FEA) simulation is utilised to identify the process temperature factors that lead to tool thermal expansion and dimensional changes that directly impact the life cycle of the coating. The theoretical and FEA results show that the mould material and the two coatings experience a significantly different thermal expansion from each other. It has also been shown that at the micro scale heat loss at the tool surface is dominant, and the variation in heat has a significant influence on the different thermal expansion rates. In particular the DLC coated micro rib features are particularly susceptible to high variations in heat transfer. The research identifies areas of the tool surface that experience sudden heat variation across the part

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Nanosecond Yb fibre laser milling of aluminium: effect of process parameters on the achievable surface finish and machining efficiency

Cited by 37 publications

References 16 publications

Ultraviolet photoluminescence in Gd-doped silica and phosphosilicate fibers

Ultraviolet photoluminescence in Gd-doped silica and phosphosilicate fibers

Achieving the Minimum Roughness of Laser Milled Micro-Impressions on Ti 6Al 4V, Inconel 718, and Duralumin

Temperature effects on DLC coated micro moulds

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