R.K.

RANA [LECTURER]
M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana LASER BEAM MACHINING

Laser1 Beam Machining (LBM)

Laser machining is a technology that uses a laser beam (narrow beam of intense monochromatic light) to cut required shapes or profile or pattern in almost all types of materials. Some of the examples include metals, ceramics, food products, leather etc. In this process, the output of a high power laser beam is directed in a programme programmed manner towards the material required to be cut. The hig high h amount of heat thus generated either melts, burns, or vaporizes away the material at the focused region. The process can be used to make precise holes in thin sheets and materials. The laser beam cutting finds its applications in a variety of fields. Th The e fields where laser beam has been successfully used are cloth and plastic cutting, laser marking, laser welding, laser drilling, cleaning and surface treatments. Principle of Laser: n by the Stimulated Emission of The word laser is an acronym2 for Light Amplification Radiation. When an atom absorbs a quantum of energy f from rom a light source, the orbital electron of an atom jumps to a higher energy level. The electron later drops to its original orbit and emits the absorbed energy. If the el electron, ectron, which is already at high energy level, absorbs the second quantum of energy, it emits two quanta of energy and after emitting the energy it returns back to its original orbit. The energy that is radiated has the same wave length as the simulating e energy. nergy. The laser material when placed in an optical cavity and exposed to light energy keeps storing the energy. The energy initially builds up in the laser material and finally gets emitted in the form of a highly amplified light beam. The basic mechanism of energy transfer in laser beam is shown in Fig. 3.1 and laser beam generation is schematically shown in Fi Fig.3.2

Figure 1: Mechanism of Energy Transfer in Laser Beam

Laser: An acronym for light amplification by stimulated emission of radiation; an optical device that produces an intense monochromatic beam of coherent light 2 Acronym: A word formed from the initial letters of the several words in the name

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana LASER BEAM MACHINING

Attributes of Laser Beam The attributes of laser light are as follows: It is coherent i.e. all photons that make up the beam are in phase with each other. This optical property of light that mostly distinguishes the laser from other light source is coherence. The laser is regarded, quit correctly as the first truly coherent light source. Other light sources, such as the sun or a gas discharge lamp, are at best only partially coherent. It is highly collimated; i.e. a parallel beam is produced. Light rays are almost perfectly parallel It is monochromatic means the light is of one co color, lor, or of one wavelength. Different media used to stimulate the photons generate different wavelengths, but each type of laser has a specific wavelength.

Figure 2: Mechanisms or Principle of Laser Beam Generation

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana LASER BEAM MACHINING

Classification of Laser Beams Laser beams can be classified in two ways as Continuous mode and Pulse mode. Continuous mode: This mode is generally preferred while cutting straight and mildly contoured paths (the cutting is fastest). Pulse mode: This mode is preferred for cutting thin materials, as it enables tight corners and intricate details to be cut without excessive burning. The representation of continuous and pulsed beam i is shown in Fig. 3.3

Figure 3: Continuous and Pulsed Beam Lasing Medium Many materials can be used as the heart of the laser. Depending on the lasing medium lasers are classified as solid state and gas laser. Solid Solid-state state lasers are commonly of the following type: Ruby which is a chromium alumina alloy having a wavelength of 0.7 m Nd-glass lasers having ng a wavelength of 1.64 m Nd-YAG YAG laser having a wavelength of 1.06 m These solid-state state lasers are generally used in material processing. The generally used gas lasers are Helium Neon Argon CO etc.
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Lasers can be operated in continuous mode or pulsed mode. Typically CO2 gas laser is operated in continuous mode and Nd YAG laser is operated in pulsed mode. Types of Laser: There are two types of lasers used for cutting: the gaseous CO2 laser and the solidstate Neodymium-doped doped Yttrium A Aluminum Garnet (Nd: YAG) laser. www.CrazyProf.in www.RamakantRana.blogspot.com

R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana LASER BEAM MACHINING

The properties of the above two types of laser are given below: CO2 Lasers: these lasers can be operated continuously and on a pulsed basis o Wavelengths: 10.6 m o Power up to 100 kW o Pulsed and continuous wave Nd: YAG Lasers: (Neodymium (Neodymium-doped, Yttrium-Aluminum- Garnet (Y3Al5O12)) o Wavelengths: 1064 nm o Power up to 5 kW o Pulsed and continuous wave The CO2 laser is more powerful amongst these lasers and is primarily used for cutting and profiling. It is capable of cutting up to 25mm thick carbon steels. This laser beam, because of the spread after its focal point, tends to create a tapered cut. The Nd: YAG laser is suitable for drilling small holes (2 (2-3 3 microns) to a depth approximately six times diameter. It can also be used for eng engraving raving and etching. A significant advantage of the Nd: YAG laser is that the beam can be transmitted through fiber-optic optic cables. This property/characteristic makes it useful for welding applications. Laser Construction: Following Figure shows a typical Nd-YAG laser. Nd-YAG laser ser is pumped using flash tube. Flash tubes can be helical, as shown in Following Figure, , or they can be flat. Typically the lasing material is at the focal plane of the flash tube. Though helical flash tubes provide better pumping, they are difficult to maintain.

Figure: Solid Solid-state laser with its optical pumping unit solid-state laser. Figure 11 shows the electrical circuit for operation of a solid The flash tube is operated in pulsed mode by charging an and d discharging of the capacitor. Thus the pulse on time is decided by the resistance on the flash tube side and pulse off time is decided ded by the charging resistance.

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

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There is also a high voltage switching s supply for initiation of pulses. Fig. 12 shows a CO2 laser. Gas lasers can be a axial flow, as shown in Fig. 12, transverse flow and folded axial xial flow as shown in Figure 13. The power of a CO2 Laser aser is typically around 100 Watt per metre of tube length. Thus to make a high power laser, a rather long tube is required which is quite inconven inconvenient. For optimal use of floor space, high high-powered CO2 lasers sers are made of folded design. In a CO2 laser, a mixture of CO2, N2 and He continuously circulate through the gas tube. Such continuous recirculation of gas is done to minimize consumption of gases. CO2 acts as the main lasing medium whereas Nitrogen helps in sustaining the gas plasma. Helium on the other hand and helps in cooling the gases. As shown in Fig. 12 high voltage is applied at the two ends leading to discharge and formation of gas plasma. Ener Energy gy of this discharge leads to population inversion and lasing action. At the two ends of the laser we have one 100% reflector and one partial reflector. The 100% reflector redirects the photons inside the gas tube and partial reflector allows a part of the laser beam to be issued so that the same can be used for material processing. Typically the laser tube is cooled externally as well. As had been indicated earlier CO2 lasers are folded ded to achieve high power. Figure 13 shows a similar folded axial flow l laser. aser. In folded laser there would be a few 100% reflective turning mirrors for maneuvering3 the laser beam from gas supply as well as high voltage supply as shown in Fig Figure 13.

Figure 11: Working of a solid solid-state laser

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Maneuvering: Act in order to achieve a certain goal

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana LASER BEAM MACHINING

CO2laser Figure 12: Construction of a C

Figure 13: Construction of folded gas laser Application Large holes upto 1.5 mm dia. Large holes (trepanned) Small holes > 0.25 mm dia. Drilling(punching or percussion) Thick cutting Thin slitting of metals Thin slitting of plastics

Type of laser Ruby, Nd-glass, Nd-YAG Nd-YAG, CO2 Ruby, Nd-glass, Nd-YAG Nd-YAG, Ruby CO2 with gas assist Nd-YAG CO2 www.RamakantRana.blogspot.com

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI Plastics Metals Organics, Non-metal Ceramics

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CO2 Nd-YAG, ruby, Nd-glass Pulsed CO2 Pulsed CO2, Nd-YAG

Process characteristics of different lasers lasers:

Mechanism of Material Removal / Cutting using Laser Beam Beam: The mechanism of material removal by laser beam is given in the following steps: Place the workpiece on the table. As there is absence of cutting forces, fewer work holding devices are needed. The focal point of the laser is intentionally focused onto the surface of the workpiece for providing the heat in a concentric manner. Due to the striking of laser beam, heat is generated at the work work-piece piece surface sur and as a result, the material vaporizes instantly, producing kerf in the material. The movement of machine machine-axis axis is through the computer control which helps to achieve the required profiles on the workpiece. Heat Affected Zone (HAZ) is minimal in laser as compared to flame cutting. To clear the molten metal that has yet not vaporized or clogged on the surface of the workpiece, the assist gas, (inert gas or exothermic gas is used for this propose) under pressure is passed on on-to the workpiece. The use of different assist gases with different work materials is given in Table 1.

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana LASER BEAM MACHINING

Table 1: Workpiece material and corresponding Assist gases Oxygen Mild steel Oxygen or nitrogen (nitrogen Stainless steel leaves an oxide free edge that can Aluminum improve Weldability) Titanium Nitrogen Nonmetals Argon (an inert gas because of its reactivity) Air or inert gas The schematic of laser cutting units are shown in Fig. 3.4 and Fig. 3.5. Referring to Figure 3.4, when power is supplied by the PFN (pulse (pulse-forming forming network), an intense pulse of light (photons) is released through one end of the crystal rod.

Figure 4: The Schematic of Laser Cutting Unit The laser light will pass on through the shutter assembly t to o the angled mirror and down through the focusing lens to the workpiece workpiece. The laser light beam is coherent and has very high energy content. When focused on the desired surface, laser light creates intense heat which can be further used for welding, cutting and drilling applications.

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana LASER BEAM MACHINING

Historical Developments Laser cutting is being used in industries since the 1970's. The first common application was for sign sign-making, making, mainly cutting acrylic. It was established as a manufacturing process in the 80s It is now become a significant process in every manufacturing economy Advantages The ability to cut almost all materials No limit to cutting paths as the laser point can move in any paths. No cutting lubricants are required As there is an absence of direct conta contact ct between the tool and workpiece; thus no forces are induced and as a result it is not necessary to provide the work holding system to hold the workpiece. The fragile materials are easy to cut on a laser without any support. Flexibility exists in precision cutting of simple or complex parts. There is no tooling cost or associated wear costs due to it. Laser produces high quality cuts without extra finishing requirements. Disadvantages Laser processes involve high capital investments and high operat operating ing costs. Laser holes are tapered to some extent (approximately 1% of the drill depth) It cannot drill blind holes to precise depths. Hence there is limitation on its thickness. Heat affected through the lasers may change the mechanical properties of the metallic materials and alloys The processing time in larger holes is slower due to trepanning action (process) involved in it. Reflected laser lights can lead to safety hazards.

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana LASER BEAM MACHINING

Assist or cover gases are required for safety purposes. Applications he problems associated with the conventional approach in cutting of One of the tough materials such as titanium alloy is that, at high cutting speeds the life of the cutting tool is very short. As the titanium alloys are used extensively in the aerospace industry, t there is a tremendous interest and curiosity for developing this technique especially for enabling higher cutting rates. Laser machining is used for making very accurate sized holes as small as 5 microns in metals, ceramics and composites without warpages. It is widely used for fine and accurate drilling and cutting of metallic and nonnon metallic materials. Electronic and automotive industries also find extensive applications for laser beam machining. The materials that can be cut by laser are extended wood, plastics, leather, glass, ceramics and fiber optics. Fig. 3 3.6 6 shows the schematic of cutting glass material through the laser machining process.

Figure 6: Laser Cutting of Glass

Figure 14: Aluminium luminium Glass Fibre Laminate heat sensitive glass fibre layer due to presence of resin as binder

Limitations: High initial capital cost High maintenance cost Not very efficient process Presence of Heat Affected Zone specially in gas assist CO2 laser cutting Thermal process not suitable for heat sensitive materials like aluminium glass fiber laminate as shown in Figure 14.

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