Self-optimizing method and software for calibration and mapping of a laser system for laser machining

Putzer, M.; Zweifel, M.; Kneubühler, F.; da Silva, G. Rogério; Michael, K.; Schröder, N.; Schudeleit, T.; Bambach, M.; Wegener, K.

doi:10.1016/j.optlaseng.2024.108245

Cited by 4 publications

(1 citation statement)

References 18 publications

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“…1. Elimination of the distortion resulting from the scanning system as for instance described in [11]. 2.…”

Section: Calibrationmentioning

confidence: 99%

Enhancing Orthogonal Finishing Machining of Ti6Al4V with Laser Modified Tools

Kneubühler,

Zhang,

Haudenschild

et al. 2024

Preprint

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Finishing machining of Ti6Al4V, known for its high strength and heat conduction resistance, demands optimisation to achieve high-quality end products. This study explores modifying the chip contact length on the rake face and altering the flank face with a cavity to minimise process forces and temperatures, while maintaining cutting edge integrity. The research validates the manufacturability of laser-modified tools through ultra-short pulsed laser ablation, indicating potential for industrial scale-up. Extensive experimental evaluations under dry conditions assess the impact of tool modifications at various feed rates for planing and turning. Significant reductions in process forces and temperatures were observed with rake face modifications, particularly at a cavity distance of approximately \qty{34}{\micro\meter}. Ideal performance was noted for feed rates between \qtyrange[range-units=single]{0.035}{0.045}{\milli\meter} for planing and \qtyrange[range-units=single]{0.040}{0.045}{\milli\meter}/rev for turning. Smoothed Particle Hydrodynamics (SPH) simulations employing a Johnson-Cook material model were used to analyse chip formation and to predict the process forces. These simulations revealed a clear change in the chip formation and lower process forces and temperatures. The SPH results closely matched experimental outcomes, with a discrepancy of less than \qty{7}{\percent} in cutting forces for both tool types, although feed forces were underestimated by about \qty{50}{\percent}. The effect o the tool modification is reflected accurately at the specified feeds.

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“…1. Elimination of the distortion resulting from the scanning system as for instance described in [11]. 2.…”

Section: Calibrationmentioning

confidence: 99%

Enhancing Orthogonal Finishing Machining of Ti6Al4V with Laser Modified Tools

Kneubühler,

Zhang,

Haudenschild

et al. 2024

Preprint

View full text Add to dashboard Cite

show abstract

Enhancing orthogonal finishing machining of Ti6Al4V with laser-ablated tool geometry modifications

Kneubühler,

Zhang,

Haudenschild

et al. 2024

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Finishing machining of Ti6Al4V, known for its high strength and heat conduction resistance, demands optimisation to achieve high-quality end products. This study explores modifying the chip contact length on the rake face and altering the flank face with a cavity to minimise process forces and temperatures while maintaining cutting edge integrity. The research validates the manufacturability of ultra-short pulsed laser-ablated tool geometry modifications, indicating potential for industrial scale-up. Extensive experimental evaluations under dry conditions assess the impact of tool modifications at various feed rates for planing and turning. Significant reductions in process forces and temperatures were observed with rake face modifications, particularly at a cavity distance of approximately 34 µm. Ideal performance was noted for feed rates between 0.035 and 0.045 mm for planing and 0.040 to 0.045 mm/rev for turning. Smoothed Particle Hydrodynamics (SPH) simulations employing a Johnson-Cook material model were used to analyse chip formation and to predict the process forces. These simulations revealed a clear change in the chip formation and lower process forces and temperatures. The SPH results closely matched experimental outcomes, with a discrepancy of less than 7 % in cutting forces for both tool types, although feed forces were underestimated by about 50 %. The effect of the tool modification is reflected accurately at the respective feeds.

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