Laser Machining

of Materials University of Twente

D reb b el Institu te The Netherlands

laser beam Surface temperature

2000
plasma
keyhole 1500 Laser Laser machining is based on the local supply of energy to materials.
beam
meltpool base material 1000 length At the surface of the material the laserlight is transformed into heat,
weld
500
which is available for processing.
0
Isotherms Process models are developed:
-0.05 1. to gain detailed physical insight in the process behavior. E.g. to
-0.1 analyze the dependency of the process outputs on the operating
-0.15 parameters (laser power, processing velocity). Or, to relate the
-0.2
Schematic overview laser welding -0.25
process results to the measurable quantities;
1900
2. for the design of model based controllers.
-2 -1 0 1 2
1800
x [mm]
1700 Theoretical models follow from the solution of the set of partial
1600
G Calculated temperature differential equations, which describe the physical phenomena of
distribution.
2000
laser surface treatment. In addition, models are determined by
1500
E Measured (green) and system identification. Basically, process identification consists of
identified (red) process adjusting the parameters of the model (e.g. a transfer function) such
1000
outputs. that the output of the model coincides well with the measured series
300 350 400 450 500 550 600 650 700
Sample number (fs=1100Hz) of inputs and outputs.

Beam
guiding Rofin Sinar 1700RF RS422 Thermal
mirror(s) CO2 laser LC The results of laser surface treatment may vary due to the sensitivity of
camera
17 mm the process to disturbances, such as varying absorptivity and the small
Laser beam dimensions of the work piece. To increase the reproducibility of the
2
2 kW, M =1.72
Nitrogen process, real-time feedback control systems are designed and tested.
150 l. min-1 Laser Controller Pyrometers
z-axis
RS422 This includes:
Copper WSC
The characterization of the laser-material interaction.
Lens mount with A/D
tube plano-convex lens The definition of the quantities to be controlled (outputs).
f =154.5mm Anti- The development of sensors to measure these outputs.
45 Nozzle aliasing
filters
The development of actuators, which allow the manipulation
CNC file
x-axis 88mm
Work Station of the outputs.
8mm Controller with a
Galil DMC-630
Analysis of the correlation between measured signals and
y-axis
v motion controller disturbances (process models & system identification).
SCHAAD
Establishment and design of a control law, based on the process
XY-table model(s).
-2 Control system for laser surface alloying, including two
(a=3 m.s )
temperature sensors (pyrometers), a thermographic
camera, a laser source, a XY-table and two process
computers.

Comparison of
MIG-welding (1) The results of process modelling and process control are tested on
and laser welding real products. De resulting knowledge is transferred to industry.
(2) of conveyor belt
parts. Only the laser
weld shows full Applications are developed in close co-operation with industry. This
penetration. co-operation may be in the form of:
Feasibility studies,
Process or product studies concerning real products.

Examples of applications are: laser cutting of high tensile steels,

high speed cutting of paper, laser drilling of thin foils for gas
filtering, laser welding of automotive tailored blanks.

An important aspect of application development is to determine

optimal and robust machining parameters (laser power and
Laser cladding of a DAF truck processing velocity). In addition to theoretic process models also
outlet valve. The resulting statistical optimalisation methods are applied.
surface shows improved wear
resistance at high temperatures.
Statistical analysis of results.

prof. dr. ir. J. Meijer Drebbel Institute, WB-WA

University of Twente
P.O. Box 217, 7500 AE Enschede
The Netherlands
drebbel@rt.el.utwente.nl
http://www.rt.el.utwente.nl/drebbel/