Laser Beam Machining (LBM)

Dr. Venkaiah N

"It is best to learn as we go, not go as we have learned."

~ Leslie Jeanne Sahler

 Learning Outcomes
At the end of this lecture, student should be able to

v Describe lasing process

v Explain the mechanism of material removal in LBM

v Identify major components of LBM

v Identify the process parameters of LBM and explain their effect

v List advantages, disadvantages and applications of LBM

 Thermal Beam Processes
108

Power density, W/mm2 107 Electric discharge

106
105 Laser beam

104
Electron beam
103
102 Welding arc

101
0
Gas flame
10
101 102 103 104 105
Spot diameter (micron)

Fig. 9.6.1 Variation in energy density with spot diameter of thermal beam
Fig. Variation in energy density with spot size
processes
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EBM and LBM are typically used with higher power density to machine
materials. The mechanism of material removal is primarily by melting and
rapid vaporisation due to intense heating by the electrons and laser beam
 LBM Features
§  LASER - Light Amplification by Stimulated Emission of Radiation.

§  Light emitted by LASER has several characteristic features (highly coherent,

monochromatic, etc.) which distinguish it from other light sources.

§  LBM utilizes a high energy beam (106 W/mm2) which can be focused upon a
small area.

§  Non-contact machining

§  Wide range of applications

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§  HAZ is small
 Patially reflecting mirror
Focusing lens
Pool Weld
Travel
Workpiece Lasing Process
direction

energy absorbed energy emitted

from flash lamp as heat
excited outer
intermediate electron
energy
ground levels

inner Stimulated absorption

electrons Fig (b).absorption
Stimulated Energy absorption
nucleus (b)
energy normal
emitted as electron
light (photon) orbits
re 1.29 Laser beam Figwelding
(a). Energy absorption
with solid-state andprocess; (b) energy absorp-
laser: (a)
and emission duringemission
longitudinal laser action.
direction Modified
during
would form coherent,from
laser highly Welding intense laser (1).
directional,Handbook
action
beam.
Fig (c).emission
Spontaneous
SpontaneousEnergy
emission emission

Stimulated
Stimulated emission
emission
Fig (d). Lasing action
Fig.Fig. 9.6.8 Spontaneous
9.6.8 Spontaneous andstimulated
and stimulatedemissions
emissions

at at higher
higher energy
energy meta-stable
meta-stable state,
state, cancanreturn
returntotothe
theground
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stateininthe
the form
form
of of an
an avalanche
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frequency or or
Fig. 9.6.9 Lasing action
 Lasing Medium
§  Solid-state lasers
•  Ruby (chromium – alumina alloy) with a wavelength of 0.7 µm
•  Nd-YAG (Neodymium-doped Yttrium Aluminium Garnet) laser
having a wavelength of 1.06 µm.
•  Nd-glass lasers having a wavelength of 1.64 µm.

§  Gas laser
•  Helium, Neon, Argon and CO2 etc.

§  Most commonly used solid-state laser is the ruby laser. 6

LBM - Schematic

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 Material Removal Mechanism
As laser interacts with the material, the energy of the photon is absorbed by the
work material leading to rapid substantial rise in local temperature. This in turn
results in melting and vaporization of the work material and finally material
removal.

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Video
 MRR
§  Volumetric removal rate (VRR) (mm3/min):

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Material Removal Mechanism

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 Process Activity
Show the lasing process using suitable sketches and discuss
with your neighbor.

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 Process Parameters

1.  Beam parameters

•  Wavelength
•  Laser intensity and spot size

2.  Process parameters

•  Process Gas and Pressure
•  Work material properties
•  Cutting Speed

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 Process Parameters …

Wavelength

² Affects material‘s surface absorptivity

² For a specific material type, there is a certain wavelength

which can have maximum absorption of laser energy with a
lowest reflection.

² Due to the shorter wavelength of fiber lasers (1 μm)

compared to CO2 lasers (10.6 μm), it leads to the higher
absorption in metallic material.

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 Process Parameters …
Laser intensity and spot size
²  High intensity corresponds to small spot size
²  High intensity leads to
•  rapid heating of the material
•  little time is available for heat to dissipate into the
surrounding material
•  Reduces reflectivity of metals
•  Higher thickness of material can be cut

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 Process Parameters …
Assist gas and Pressure
§  Gas jet is directed with the laser beam into the interaction region to remove
the molten material from the machining region
§  Also shield the lens from the expelled material by setting up a high-pressure
barrier at the nozzle opening
§  Pure oxygen à rapid oxidation and exothermic reactions à better process
efficiency
§  Inert gas (helium or argon) à improves quality of cut edge
§  The smaller the diameter of the gas nozzle and the shorter its distance from
the workpiece surface, the better is the quality of the cut.
§  Gas pressure also plays a significant part in the determination of quality and
rate of machining

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 Process Parameters …
Cutting Speed ! Inversely proportional to the thickness
²  The cutting speed must be balanced with the gas flow rate and the power.
²  Higher cutting speed
§  cutting time decreases,
§  less time for the heat to diffuse sideways and
§  the narrower the HAZ
§  kerf is also reduced
§  However, striations on the cut edge become more prominent
§  penetration is lost
²  Lower cutting speed
§  excessive burning of the cut edge à which degrades edge quality
§  Increases HAZ
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 Process Parameters …
Material properties
²  The removal rate is enhanced for materials of
§  low thermal conductivity,
§  low reflectivity,
§  low density
§  low latent heat (low melting point)
§  low specific heat

²  Non-metals like plastics are easier to be processed

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 Process Activity
List some important process parameters and outline their
effect

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 Advantages
§  No tool wear and associated costs
§  No need of fixtures to hold workpiece
§  The fragile materials are easy to cut
§  Holes can be located accurately by using an optical system for
alignment
§  Very small holes with a large aspect ratio can be produced
§  A wide variety of hard and difficult-to-machine materials can be
tackled
§  Machining is extremely rapid and the setup times are economical
§  Holes can be drilled at difficult entrance angles (10° to the
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surface)
 Limitations
§  High equipment cost.

§  The thickness of the material that can be laser drilled is restricted

to 50 mm.

§  Adherent materials, which are found normally at the exit holes,

need to be removed.

§  Reflected laser lights can lead to safety hazards.

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 Applications
§  Any non-reflective material can be cut

§  Very accurate sized holes as small as 5 microns in metals,

ceramics and composites without warpage.

§  Trepanning à Used for large holes

§  Texturing: Textured steel and aluminum strips or sheets are

widely used in cars

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