Laser Beam Machining

Guided by : Mr. Satish S

Contents
Introduction What is LBM? Three important attributes of laser light Mechanism of metal removal Design considerations Laser beam machining parameters Process characteristics Advantages and Limitations Applications

Introduction
The word LASER stands for Light Amplification by Stimulated Emission of Radiation. Laser cutting is mostly a thermal process in which a focused laser beam is used to melt material in a localized area. A co-axial gas jet is used to eject the molten material from the cut and leave a clean edge. A continuous cut is produced by moving the laser beam or work piece and leave a clean edge. A particular characteristic of a laser cut is the formation of striations on the cut edge. These striations play an important part in laser cutting as they effectively control the edge roughness. In 1965, the first production laser cutting machine was used to drill holes in diamond dies. This machine was made by the WESTERN ELECTRIC ENGINEERING RESEARCH CENTER. There are three main types of lasers used in laser cutting. The CO2 laser is suited for cutting, boring, and engraving. The neodymium (Nd) and neodymium yttriumaluminum-garnet (Nd-YAG) lasers are identical in style and differ only in application. Nd is used for boring and where high energy but low repetition is required. The Nd-YAG laser is used where very high power is needed and for boring and engraving.

What is LBM?
Uses a concentrated beam of light to vaporize part of the work piece Usually produces a rough surface with a heataffected zone Can cut holes as small as .005 mm with depth/diameter ratios of 50:1

Three most important attributes of laser light

It is coherent i.e. all photons that make up the beam are in phase with each other. It is collimated, because photons that diverge from the parallel are lost through the chamber walls a very parallel beam is issued. It is monochromatic, literally one colour , that is of one wavelength. Different media used to stimulate the photons generate different wavelengths, but each type of laser has a specific wavelength (e.g. CO2 is 10.6 mM). The purity of the medium used is of paramount importance.

LBM

Mechanism of Metal Removal

The mechanism by which a laser beam removes material from the surface being worked involves a combination of the melting and evaporation processes. However, with some materials, the mechanism is purely one of evaporation.

Mechanism of Metal Removal

THERMAL FEATURES OF LASER MACHINING.
The radiant energy delivered to a surface by a focused laser beam is consumed in four ways; A part is reflected and lost (this part becomes larger in the case of highly reflective metal surfaces). Most of the energy which is not reflected is used for melting metal. A relatively small part of the energy is used to evaporate the liquid metal. A very small part of the energy is conducted into the unmelted base material. The relative magnitudes of the heat consumption at these four avenues strongly depend upon the thermal and optical properties of the material being worked and the intensity and pulse duration of the laser beam. It is seen that all the energy that leaves the laser head does not reach the material surface; some is absorbed on the way. Part of the material is expelled from the surface stays in the path of the beam in the form of small droplets and continues to absorb energy. This represents a definite loss in the thermal efficiency, the importance of which has not yet been quantitatively assessed.

Example of a part cut by laser-beam machining Splatter marks appear where the laser first cuts into the material

Design Considerations:

-Non-reflective work piece surfaces are preferable -Sharp corners are difficult to produce; deep cuts produce tapers -Consider the effects of high temperature on the work piece material

Laser Beam Machining Parameters

(A) PULSE FREQUENCY. As with the laser power, the pulse frequency can be matched to the relevant machining task. For example, it is recommended small contours are cut with reduced pulse frequency. The pulse frequency is also reduced when piercing in the ramp mode. (B) CUTTING SPEED. The cutting speed must be matched to the type and thickness of the workpiece. A speed which is too fast or too slow leads to increased roughness, burr formation and to large drag lines. (C) MATERIAL THICKNESS. With increasing material thickness the roughness of the cut edges increases for metallic materials and the laser power required for cutting is greater. With greater material thicknesses noticeably lower cutting speeds are achieved for the same laser power.

Laser Beam Machining Parameters

(D) FOCUSSING LENS. The focusing lens must be installation correctly. The surface which curves outwards must always point to the top.

A dirty focusing lens heats up due to more intense absorption of the laser radiation and deforms. This leads to the focal position drifting towards the top. (E) NOZZLE DISTANCE. The nozzle distance is held at the programmed value with a capacitive height control without touching the work-piece. The nozzle distance between the work-piece and the material surface has a great effect on the cutting quality with laser cutting. The smaller the nozzle distance, the better the cutting quality. But there is the following restriction: To ensure safe cutting, a minimum distance should not be maintained. This minimum distance is approx. 0.025. For hole piercing the nozzle distance is selected to be the same or larger depending on the material thickness and type of hole-piercing.

Laser Beam Machining Parameters

(F) WORK PIECE SHAPE. Certain shapes of the work-piece, such as fine bridges, acute angles, or small holes (edge length / diameter small than 2x sheet thickness) sometimes give problems with laser cutting. These geometrical elements are therefore cut with reduced parameters: reduced laser power reduced cutting speed lower pulse frequency Otherwise there is the risk that too much heat will be applied to the work-piece and parts of the (G) WORKPIECE SURFACE. Shiny material surfaces, such as for example pure aluminum, produce strong reflection of the laser beam and therefore also poor cutting results. With laser cutting, rolling marks and grooves, stamps and mechanical damage to cavities deflect laser beams and gas flows in undefined directions. This is more noticeable with thick sheets and causes unclean cut edges and it reduces cutting speed and performance.Spray finishes and paint and plastic coatings affect the cutting result. Mill scaleon the on the surface of the sheet impairs the cutting result. A loose mill scale of varying thickness does not permit the focused laser beam to impinge directly on the surface. The cutting gas enveloping the laser beam is also deflected.

Laser Beam Machining Parameters

(H) CUTTING NOZZLE AND NOZZLE SIZE. The selection of the correct nozzle for the process is very important. For example, with high pressure cutting, nozzles with a larger hole are used than for standard cutting. A deformed nozzle hole, e.g. oval-shaped after a collision, can as with an eccentric laser beam, lead to directionally dependent cutting errors. In general the nozzles specified in the data sets can be used. If the nozzle is slightly too large, cutting gas consumption is increased, but the cutting quality is not significantly affected. If the nozzle is too small, the cut edge is not cleanly cut and slag clings to the lower edge of the kerfs. In the extreme case the material is not parted.

(I) ACCELERATION.
The acceleration is linked to the machine constants and generally it does not need any attention since it is a setting specific to the machine. With high pressure cutting the acceleration should be limited from about 1/8 sheet thickness, because the cutting process can easily be interrupted if the acceleration is too high.

Laser Beam Machining Parameters

(J) FOCUS POSITION.

Exact positioning of the focal point is an important requirement for good cutting results. Basically the following applies for the laser-beam torch cutting of carbon steel: For sheet thicknesses up to about 6 mm the optimum focal position is on the sheet surface. With sheet thicknesses of 8 mm and over, the focal point must be positioned above the sheet surface. High pressure cutting of stainless steel or aluminum: The focus is positioned in the sheet. As a rule of thumb, the focus position can be positioned at about 2/3 the sheet thickness in the sheet. Therefore, each change of plate thickness normally means a change of focus position.

Laser Beam Machining Parameters

(K) CENTRING THE NOZZLE. The focusing lens must be set such that the focused laser beam is placed in the centre of the nozzle hole. The focused laser beam may at most be +0.002 off centre with respect to the nozzle. With otherwise good cutting quality, a non-centered laser beam can lead to the cutting quality being dependent on direction. In the extreme case the cut is very good in one direction and in the other directions the material is not cleanly cut or even not parted. With the torch cutting of carbon steel sparks can form on the surface of the sheet when cutting takes place in a direction opposed to the eccentricity.

1 = Nozzle Orifice. 2 = Laser Beam.

a is centered, b and c are not centered.

Process Characteristics
(a) PULSE FREQUENCY V/S MATERIAL REMOVAL RATE.

Process Characteristics
(b) PULSE FREQUENCY V/S DEPTH (c) MACHINING DEPTH OF CUT V/S ENERGY CONSUMPTION.

Process Characteristics
(d) PULSE FREQUENCY V/S SURFACE ROUGHNESS. (e) LASER FREQUENCY V/S ABLATION RATE.

Process Characteristics
(f) LASER POWER V/S CUTTING RATE. (g) PULSE ENERGY V/S TIME.

Advantages
Non contact processing Capability of automation Reduced manufacturing costs Efficient material utilization Reduced heat-affected zone (HAZ) High productivity

Limitations
Its overall efficiency is extremely low(10-15%). The process is limited to thin sheet plates . Low material removal rate. The machined holes are not round and straight. Life of flash lamp is short. Effective safety procedures are required. Cost is high.

Applications
The LBM process can make holes in refractory metals and ceramics and in very thin materials without warping the work piece. The laser can scribe, drill, mark, and cut thin metals and ceramics, trim resistors, and process plastics, silicon, diamond, and graphite with tolerances to one micron. LBM can make very accurate holes as small as 0.005 mm in refractory metals ceramics, and composite material without warping the work pieces. Laser beam cutting (drilling). A gas jet (typically, oxygen) can further facilitate this phase transformation and departure of material removed. Laser drilling should be targeted for hard materials and hole geometries that are difficult to achieve with other methods. Laser beam cutting (milling) A laser spot reflected onto the surface of a work piece travels along a prescribed trajectory and cuts into the material.

Thank You

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