KALEEM UZ ZMAN

ROLL NUMBER: 03
ENROLLMENT NUMBER:443\14
Deparment of Metallurgy &Meterial
Sciences
NIT Srinagar
1) INTRODUCTION
2) ANALYSIS OF CUTTING RESULT
3) CUTTING RESUTLS AND ANALYSIS
 SUPERSONIC NOZZLE
 OBROUND SHAPED NOZZLE
4) CONCLUSIONS
5) REFERENCES
 The diode laser have come into picture recenty ,especially
after considerable improvement in laser beam quality that
have enabled laser cutting appplications .These are
established Technologies in other laser processsing fields,
but also the main pumping technology used for fibreand
disk technologies.Diode lasers are thus potentailly the
cheaptest laser technology,as compactness or maintence
requirements. Recent research has shown a great
potentail of polorization control in laser cutting with diode
laser. These developments introduce new variables in the
cutting process that must be considered.The geometries
are responsible for different kerf information. The assist
gas flow is intrinscally connnected to thoese change and
needed to be optimized for the new conditions.
Table gives an overview of the significant effects encounted
for the three measured responses, after separately fitting a
least square model to each respose .Average dross height
has a considerably lower RSquare valve which could be
releated to errors induced by fallen dross before the actual
measurement (both during sectioning and handling of the
cut samples). Tye focal point position is clearly the most
significant effect for al responses .it is important to notice
that ,acccording to the results, a higher focal point
position will increase both the maximum cuttting speed
and the amount of dross while making a smaller kerf
width. The effect of gas pressure as well, which in contrast
to what was initially thought , is not significant for all
measured responses,with the exception of a 3rd
ordeinieraction (o*SOD*P) for the maximum cutting
speed.
This could be related with the position of the shock waves in relation to the kerf and , thus,
related to the amount of the gas flowing into the cutting kerf
max.cutting kerf
Avg..dross
Table 1 speed width
height
Rsquare 0.88 0.93 0.53
F 12312 (+) 26349 (-) 6402 (+)
D*F 4824 n.s n.s
O*F 4774 n.s 1890
O 4607 (+) n.s n.s
O*O 4334 n.s n.s
O*D*F 3752 n.S n.S

O*D 3279 4313 n.s

O*SOD*D 3165 n.s n.s
O*SOD*P 2817 n.S n.s
Table 1: Significant effects listed (Logworth =
-log(p-value) for the measured responses.
n.s –stands for non-significant value (at p –
value greater than 0.05).+ and – signs for
main effects indicate a generally positive or
negative influence on the responsae value .
 Supersonic nozzle :
A total of 4 extra tests were realized with the
supersonic nozzles , as depicted in table 2. It is clear
that the target of decrasing attached dross was not
achieved. The cutting speed also decreases if we
compare it with the best maximum cutting speed
obtained in the benchmarking tests at offset zero and
similar SOD and F conditions. The limitations in the
minimum throat diameter imposed by the laser beam
quality were responsible for a mimimum throat of 3
mm and consequently an even bigger exit
diameter.on one hand ,the cooling effects of the
impinging gas on the metal sheet plate may be
playing a bigger role than initailly expected and
responsible for the lower cutting speed.
 On the other hand the creation of a strong vortex at the kerf
entrance may be blocking the entrance of a uniform
accelerated flow into the cutting kerf.
 Table 2: Cutting tests performed with supersonic nozzle
show lower speed &no improveme/t in dross level

Nozzle SOD F Maximum Kerf width Average

type cutting [mm] dross
speed heght
[mm/mim] [mm]

Linear 0,5 -1,5 1050 (- 0,47 0,75

25%)
MLN 0,5 -1,5 1150 (- 0,49 0,31
21%)
Linear 1,0 -1,5 1050 (- 0,44 0,61
19%)
MLN 1,0 -1,5 1100 (-15) 0,41 0,40
 The obround shape nozzle was tested at the
focus point position of -1,5 mm and SOD of
1mm for two levels of pressure ,15 and 17,5
bar. For both cases the cuttting speed is
higher ,4 and 11 %respectfully, when
comparing similar conditions with a 1,5 mm
standard conical nozzle. This us however
accompanied by a significant incresase of
dross and a decrease of kerf width as can be
seen in table 3
Nozzle SOD P Maximum Kerf width Average
type cutting [mm] dross
sped[mm/ height
mm] [mm]
Obround 0,5 15,0 1400 0,41 (-9%) 0,46
(+4%) (+53)
obround 0,5 17,0 1450 0,36 (- 0,53
(+11) 23%) (+231)
 The benchmarking tests performed with a linearly
polarized setup in a 3 mm stainless steel sheet have
revealed the copmlexity associated with laser fusion
cutting. The interpretation of effects and iteractions
between the different parameters on maximum cutting
speed, kerf width and average dross shed a light on:
 Focus position : highly significant for kerf
formation.Hightest cutting speeds are achieved in
diameters of dross formation at a focal point positioned in
the middle of the sheet. A lower focus allows dross free
cuts at lower cutting speeds .
 Laser to nozzle offset: A significant improvement in
cutting speed was found,even considering the expected
high power loss at the nozzle tip .
 Laser beam quality : It is a limiting factor for parameters
such as offset, nozzle diameter and focal point position
due to interaction between the laser and nozzle tip.
 Two nozzle design concepts were proposed and tested:
 Supersonic nozzle for increase gas to melt momentum
exchange :Two nozzle designs were tested for a Mach 2
flow. The miknimum length nozzle showed the promising
pattern in schlieren setup. Ultimately at a lower dross
level was not achieved and the cutting speeds decreased.
The bigger throat and exit diameter imposed by the laser
quality may be responsible for unwanted cooling and
turbulent effects.
 The obround shaped nozzle : A non – axis symmetric
nozzle was designed that is capable of an offset like
condition while maintaining similar gas condumption as a
standard 1,5 mm diameter nozzle . Improvements in
cutting speed of upto 11% were possible but came at the
expense of a high dross level .
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