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Uniform rectangular moving heat source: Rectangular heat source of dimension l < x < l and b < y < b i.e. for semi-infinite body moving with constant velocity v from time t = 0 to t = t. Heat intensity I is given by,


slide-1
SLIDE 1
  • Uniform rectangular moving heat source:

Rectangular heat source of dimension –l < x < l and –b < y < b i.e. for semi-infinite body moving with constant velocity v from time t’ = 0 to t’ = t. Heat intensity I is given by, where A = 4*b*l Integrating with the space variables,

2 3

2 ' ( ) e x p [ ] 4 ( ') P d t z d T t a t t = − −

Results can be obtained by numerical integration with respect to time.

3 2 2

4 ( ') 4 ( 4 ( ')) (( ') ') ( ') 2 e x p [ ] ' e x p [ ] ' 4 ( ') 4 ( ')

l b l b

a t t b l C a t t x v t x y y d x d y a t t a t t ρ π

− −

− − − − − − − − −

slide-2
SLIDE 2

Comparison of Gaussian and uniform heat source: for EN 18 steel

Results:

No 1 2 3 4 5

  • Fig. Comparison of

width/depth of hardened zone[13]

Results:

slide-3
SLIDE 3

Finite difference formulation:

  • Nodal points
  • Nodal network
  • Regular or irregular
  • Types - coarser
  • fine

……Temperature at time interval t

slide-4
SLIDE 4

Finite Element Models

02/08/10

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SLIDE 5

Thermal Modeling

– Heat generated in workpiece due to cutting is small compared to the heat generated by the laser – A scaled model (5mm x 2mm x 2mm) is used – The Gaussian distribution of laser power intensity Px,y is given by:

=

2

2 2

tot

r exp P P

– The average absorptivity of incident irradiation is determined experimentally – Temperature dependent thermophysical properties are used

=

2 2 b b tot y , x

r exp r P π

slide-6
SLIDE 6

Mathematical Formulation

x T V c t T c Q z T k z y T k y x T k x

p p .

∂ ∂ + ∂ ∂ = +

∂ ∂ ∂ +

∂ ∂ ∂ +

∂ ∂ ∂ ρ ρ

  • T(x, y, z, 0) = T0
  • )

( ) (

4 4

= − + − + − ∂ ∂ T T T T h q n T k σε

  • 0 =

− + − ∂ ∂ ) T T ( h q n T k

e 61 1 3

10 4 2

. e

T . h ε

× =

,

!!!"

slide-7
SLIDE 7

Mathematical Formulation

  • Average measured temperatures are used for boundary

conditions on remaining external surfaces

  • Half symmetry used at bottom face

=

bottom

q =

bottom

q

slide-8
SLIDE 8

Case Study- Thermal Model

1

JUL 19 2006 14:52:01 ELEMENTS MAT NUM Natural B.C. on front face

Y

  • Mapped dense mesh (25 µm x 12.5 µm x 20µm)
  • An 8 noded 3-D thermal element (Solid70) is used
  • Gaussian distribution of heat flux applied to a 5x5 element matrix

which sweeps the mesh on the front face

X Y Z

Symmetry B.C. on bottom face X Z

slide-9
SLIDE 9

Temperature Simulation

1 JUL 20 2006 10:37:08 NODAL SOLUTION STEP=41 SUB =10 TIME=6 TEMP (AVG) RSYS=0 SMN =150 SMX =1876

Y

1 JUL 20 2006 10:37:08 NODAL SOLUTION STEP=41 SUB =10 TIME=6 TEMP (AVG) RSYS=0 SMN =150 SMX =1876

Y

MX

150 341.827 533.653 725.48 917.307 1109 1301 1493 1685 1876

(Laser scan direction) X

MX

150 341.827 533.653 725.48 917.307 1109 1301 1493 1685 1876

(Laser scan direction) X

#$$%& '(% ' $$)$% 'µ$%*"

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SLIDE 10

Laser Cutting

ME 677: Laser Material Processing Instructor: Ramesh Singh

Laser Cutting

1

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SLIDE 11

Outline

  • Materials Processing Parameters
  • Process Description
  • Mechanisms of Laser Cutting

ME 677: Laser Material Processing Instructor: Ramesh Singh 2

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SLIDE 12

Effect of Power Density

  • Power density is the key process driver
  • Power Density (Intensity)= P/πr2

ME 677: Laser Material Processing Instructor: Ramesh Singh 3

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SLIDE 13

Process Variables for Material Processing

  • The other important process variables:

ME 677: Laser Material Processing Instructor: Ramesh Singh 4

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SLIDE 14

Interaction Time and Empirical Process Chart

  • Interaction time, τ = 2 r/v

where r = beam radius and v = velocity

ME 677: Laser Material Processing Instructor: Ramesh Singh 5

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SLIDE 15

Structural Steel

ME 677: Laser Material Processing Instructor: Ramesh Singh 6

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SLIDE 16

Cutting

  • Laser cutting is able to cut faster and with a

higher quality then competing processes:

– Punch, plasma, abrasive waterjet, ultrasonic,

  • xyflame, sawing and milling

ME 677: Laser Material Processing Instructor: Ramesh Singh

  • xyflame, sawing and milling
  • Can be automated
  • 80% industrial lasers in Japan are used for

metal cutting

7

slide-17
SLIDE 17

ME 677: Laser Material Processing Instructor: Ramesh Singh 8

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SLIDE 18

Typical Cutting Setup

ME 677: Laser Material Processing Instructor: Ramesh Singh 9