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Nonlinear Dynamics of Laser-Processing NLD

Modelling,
Model Reduction
and
Simulation
of Laser Processing

© Fraunhofer ILT
Nonlinear Dynamics of Laser-Processing NLD 2

Meta-Modelling and Customer Simulation Tool:


interactive communication
Feedback
from real world use:
Business Case Customer Simulation Tool
Business Opportunity CST Emulator

Image
courtesy of Siemens

Beam / Process Detailed Meta-Model


monitoring Numerical Simulation Data Exploration

The “Visual Design Tool” developed for taper design of effusion cooling channels in laser drilling. Experimental evidence obtained
from diagnosis and theoretical knowledge from simulation provide reference data for a Metamodel.
Extracting the relevant information using the fast and efficient “Vis ual Des ign Tool ” enables
interactive communication and fast iteration design cycles.

In: The Theory of Materials Processing, Dowden, Schulz (eds.)


Nonlinear Dynamics of Laser-Processing NLD 3

Methods of Model Reduction

Phenomenological Model Reduction


 Making implicit knowledge explicit – observations relevant for modeling

Mathematical Model Reduction


 Asymptotic Analysis – Time Scale Separation – Inertial Manifold
 Variational Form ulation of PDE‘s
 Singular Perturbation

Numerical Model Reduction


 Proper Orthogonal Decomposition POD

Data Driven Model Reduction


 Meta-Modeling – data interpolation for fast access
 Design of Experiment DoE – identify significant data
Nonlinear Dynamics of Laser-Processing NLD 4

Methods for Model Reduction – the key for

fast and frugal simulations


Dilemma by Hypothesis
to be solved enriching sparse, real data to be prooven
1. Phenomenological Model Reduction
applicability – specialized
method – strong, fast, frugal, economic

• Experience suggesting parametrized formulae/equations


method – weak, uneconomic, unexplored

Digitized enrichment
2. Mathematical Model Reduction

„ Digital Guess“

of sparse data
• Asymptotic Analysis
Applicability
Strength

• Singular Perturbation

3. Numerical Model Reduction


applicability – general

• Proper Orthogonal Decomposition POD

4. Data Driven Model Reduction


• Meta-Modelling – data interpolation for fast access

• „Digital Guess“
enriching sparse, real data
• Design of Experiment DoE
Nonlinear Dynamics of Laser-Processing NLD 6

The
Dynamic Cutting Front
Story
Nonlinear Dynamics of Laser-Processing NLD 7
Nonlinear Dynamics of Laser-Processing NLD 8

Phenomena and Scales in sheet metal cutting

20 µm 80 µm 200 µm 8 mm length

gas liquid solid scales

2 µs 100 µs 1 ms time

gas liquid solid scales


Nonlinear Dynamics of Laser-Processing NLD 9

Ripple pattern
changing with
modulation frequency
of laser power
Nonlinear Dynamics of Laser-Processing NLD 10

Ripple formation is a characteristic property of cutting

Beam radius 𝑤0
For ripples of 1. kind
melt flow can be neglected
Absorption
front Melting
Ripples Cut surface front

1. kind

2. kind
𝑑𝑚
Melt film thickness

3. kind
feeding 𝑣0

Formulation of a „One-Phase Problem“ is reasonable


Nonlinear Dynamics of Laser-Processing NLD 11

Free Boundary Value Problem – the One Phase Problem

𝜕𝑇
= 𝜅∆𝑇 , 𝑇 = 𝑇 𝑥, 𝑡 , 𝑥 ∈ Ω(𝑡)
𝜕𝑡
𝐼 𝑥, 𝑡 = 𝐼0 𝑡 𝑓 𝑥 − 𝑣𝑡, 𝑡
0<𝑓<1 melting front Γ𝑚 (t):
𝑞𝐴 − 𝜆𝛻𝑇 = 𝜌𝐻𝑚 𝑣𝑏 , 𝑥 ∈ Γ𝑚 (t)
𝑇 = 𝑇𝑚 , 𝑥 ∈ Γ𝑚 (t)
sheet surface and cut surface:
𝑞𝐴 − 𝜆𝛻𝑇 = 0 , 𝑥 ∈ Γ+ 𝑡 \Γ𝑚 (𝑡)
bottom sheet surface Γ− (t):
𝛻𝑇 ∙ 𝒏 = 0 , 𝑥 ∈ Γ− (𝑡)
outer boundary:
𝑇𝑥 ∞ = 𝑇𝑎 , 𝑥 ∈ Ω(𝑡)

𝑞𝐴 = 𝐴 𝑒𝑧 ∙ 𝑛 𝐼(𝑥, 𝑡)(−𝑒𝑧 ∙ 𝑛)
Nonlinear Dynamics of Laser-Processing NLD 12

Estimates for length and time scales

Lengths: 𝛿 Velocities:
Convection-diffusion-equation with external sources

Length scales:

Time scales:
Nonlinear Dynamics of Laser-Processing NLD 13

Estimates for length and time scales

Lengths: 𝛿 Velocities:
Convection-diffusion-equation with external sources

Length scales:

Time scales:
Nonlinear Dynamics of Laser-Processing NLD 14

Smallness parameters

𝜅
𝛿= ≪ 𝑤0 ≪ 𝑑:
𝑣𝑜
𝛿2
𝑥 = 𝛿𝜉, 𝑦 = 𝑤0 𝜂, 𝑧 = 𝑑𝜁, 𝑡 = 𝜏
𝜅

2 2
𝜕𝜃 𝜕𝜃 𝜕 2 𝜃 𝛿 𝜕2𝜃 𝛿 𝜕2𝜃
= + 2+ +
𝜕𝜏 𝜕𝜉 𝜕𝜉 𝑤0 𝜕𝜂2 𝑑 𝜕𝜁 2
Nonlinear Dynamics of Laser-Processing NLD 15

2 2
Motion Equation and 𝜕𝜃 𝜕𝜃 𝜕 2 𝜃 𝛿 𝜕2𝜃 𝛿 𝜕2𝜃
= + + +
smallness parameters: 𝜕𝜏 𝜕𝜉 𝜕𝜉 2 𝑤0 𝜕𝜂2 𝑑 𝜕𝜁 2

Structure of Solution:

1D 2D 3D

Position 𝐴 of melt front Position 𝐴, Radius 𝛼 of melt front Axially distributed


Penetration Q of heat Penetration Q of heat Position 𝐴, Radius 𝛼, Penetration Q of heat
𝜉 = 𝐴(𝜏)
Tem perature

𝑄(𝜏)

Depth

most relevant bit of information


Nonlinear Dynamics of Laser-Processing NLD 16

Steeply inclined cutting front

With courtesy of
Fraunhofer ILT, Thomas Molitor
Nonlinear Dynamics of Laser-Processing NLD 17

One-dimensional One Phase Problem – PDE


𝑤02
Scales: 𝑇 = 𝑇𝑚 − 𝑇𝑎 𝜃 + 𝑇𝑎 , 𝑥 = 𝑤0 𝜉 , 𝑡= 𝜏, 𝑇 = 𝑇 𝑥, 𝑡 , 𝑎 𝑡 = 𝑤0 𝐴(𝜏)
𝜅

Parameters:

𝜕𝜃 𝜕 2 𝜃
= , 𝜉 ∈ [𝐴 𝜏 , +∞)
𝜕𝜏 𝜕𝜉 2

Heating phase Melting phase

𝜕𝐴(𝜏) 𝜃 =1, 𝜃 =0
=0, 𝜃 =0 𝜉=𝐴(𝜏) 𝜉 ∞
𝜕𝜏 𝜉 ∞

𝜕𝜃 𝜕𝜃 𝜕𝐴(𝜏)
𝛾 𝜏)𝑓(𝐴 𝜏 − 𝑃𝑒 𝜏 + =0 𝛾 𝜏)𝑓(𝐴 𝜏 − 𝑃𝑒 𝜏 + = ℎ𝑚 >0
𝜕𝜉 𝜉=𝐴(𝜏)
𝜕𝜉 𝜉=𝐴(𝜏)
𝜕𝜏
Nonlinear Dynamics of Laser-Processing NLD 18

One-dimensional One Phase Problem – exact PDE solution

Explicit solution for the heating phase

Non-linear integral equation and ordinary differential equation for melting phase
Nonlinear Dynamics of Laser-Processing NLD 21

Contents

• Overview and dynamics of cutting


• Temperature and heat flux into the sheet metal
needed for cutting
• Energy balance for thermal energy
• Fourier‘s Law
• Approx im ate Dy nam ical S y s tem in 1D
• Temperature in the sheet metal
and
heat flux into the sheet metal
needed for cutting (cylindrical source)
Nonlinear Dynamics of Laser-Processing NLD 22

Overview
Nonlinear Dynamics of Laser-Processing NLD 23

Dynamics of cutting
Nonlinear Dynamics of Laser-Processing NLD 24

1D-Dynamics of cutting:
front position 𝒂(𝒕)

𝒂(𝒕)
𝑨 𝝉 =
𝒘𝟎
What parameters are expected
to span the Inertial Manifold?
Nonlinear Dynamics of Laser-Processing NLD 25

1D-Dynamics of cutting:
front position 𝒂(𝒕), penetration depth 𝜹(𝒕) of heat and temperature 𝑻𝒔 (𝒕)

𝒂(𝒕)
𝑨 𝝉 =
𝒘𝟎
𝑻𝒔 (𝒕) − 𝑻𝒂 𝜹 (𝒕)
𝜽𝒔 𝝉 = Q 𝝉 =
𝒓𝒎
𝑻𝒎 − 𝑻𝒂
Something else
to span the Inertial Manifold?
Nonlinear Dynamics of Laser-Processing NLD 26

1D-Dynamics of cutting:
front position 𝒂(𝒕), penetration depth 𝜹(𝒕) of heat and temperature 𝑻𝒔 (𝒕)

𝒂(𝒕)
𝑨 𝝉 =
𝒘𝟎
𝑻𝒔 (𝒕) − 𝑻𝒂 𝜹 (𝒕)
𝜽𝒔 𝝉 = Q 𝝉 =
𝒓𝒎
𝑻𝒎 − 𝑻𝒂
Something else
to span the Inertial Manifold?
Nonlinear Dynamics of Laser-Processing NLD 27

2D-Dynamics at the apex:


front position 𝒂(𝒕) , front radius 𝒓𝒎 𝒕 , penetration depth 𝜹(𝒕) of heat and temperature 𝑻𝒔 (𝒕)

𝒂(𝒕) 𝒓𝒎 (𝒕)
𝑨 𝝉 = 𝜶 𝝉 =
𝒘𝟎 𝒘𝟎
𝑻𝒔 (𝒕) − 𝑻𝒂 𝜹 (𝒕)
𝜽𝒔 𝝉 = Q𝝉 = 𝒓𝒎
𝑻𝒎 − 𝑻𝒂

RQ: Impact of front radius 𝜶 𝝉 ?


RH: ?
Nonlinear Dynamics of Laser-Processing NLD 28

2D-Dynamics at the apex:


front position 𝒂(𝒕) , front radius 𝒓𝒎 𝒕 , penetration depth 𝜹(𝒕) of heat and temperature 𝑻𝒔 (𝒕)

𝒂(𝒕) 𝒓𝒎 (𝒕)
𝑨 𝝉 = 𝜶 𝝉 =
𝒘𝟎 𝒘𝟎
𝑻𝒔 (𝒕) − 𝑻𝒂 𝜹 (𝒕)
𝜽𝒔 𝝉 = Q𝝉 = 𝒓𝒎
𝑻𝒎 − 𝑻𝒂

RQ: Impact of front radius 𝜶 𝝉 ?


RH: front radius 𝜶 𝝉 is slaved – no feedback!
Nonlinear Dynamics of Laser-Processing NLD 29

Temperature and heat flux


into the sheet metal
needed for cutting
Nonlinear Dynamics of Laser-Processing NLD 30

The heat flux into the sheet metal needed for cutting

Stefan-Signorini- Condition
𝐴 𝑺 − 𝒒𝜆 ∙ −𝒏 = 𝜌𝐻𝑚 𝑣𝑏

𝑺 Poynting vector

𝒒𝜆 ∙ −𝒏 = −𝜆 𝜵𝑇 ∙ −𝒏

Ansatz from heat conduction?


Nonlinear Dynamics of Laser-Processing NLD 31

The heat flux into the sheet metal needed for cutting
first the 1D-case
scaling

Buckingham: Three independent parameters

𝜅 𝜆 𝑇𝑚 − 𝑇𝑎
𝑤0,𝑠𝑐𝑎𝑙𝑒 =𝛿= , 𝑞𝑠𝑐𝑎𝑙𝑒 =
𝑣0 𝑤0
Nonlinear Dynamics of Laser-Processing NLD 32

Scaled heat flux at the boundary – cutting front

𝑤02
𝑇 = 𝑇𝑚 − 𝑇𝑎 𝜃 + 𝑇𝑎 , 𝑥 = 𝑤0 𝜉 , 𝑡= 𝜏, 𝑇 = 𝑇 𝑥, 𝑡 , 𝑎 𝑡 = 𝑤0 𝐴(𝜏)
𝜅

𝜕𝑇 𝜆 𝑇𝑚 − 𝑇𝑎 𝜕𝜃
𝑞𝜆 = −𝜆𝛻𝑇: 𝑞𝜆 = −𝜆 = −
𝜕𝑥 𝑥=𝑎 𝑡
𝑤0 𝜕𝜉 𝜉=𝐴 𝜏
Nonlinear Dynamics of Laser-Processing NLD 33

The heat flux into the sheet metal needed for cutting
first the 1D-case

Stationary solution:
𝜃 𝜉, 𝜏 = 1 ∙ exp(−𝑃𝑒(𝜉 − 𝐴 𝜏 )

Check the stationary solution!

𝑎(𝑡)
𝐴 𝜏 =
𝑤0 𝛿 (𝑡)
Q𝜏 = 𝑤
𝑇𝑠 (𝑡) − 𝑇𝑎 0
𝜃𝑠 𝜏 =
𝑇𝑚 − 𝑇𝑎
Nonlinear Dynamics of Laser-Processing NLD 34

The heat flux into the sheet metal needed for cutting
first the 1D-case

Stationary solution:
𝜃 𝜉, 𝜏 = 1 ∙ exp(−𝑃𝑒(𝜉 − 𝐴 𝜏 )
𝜕𝐴
Check the stationary solution! = 𝑃𝑒 , A 𝜏 = 𝑃𝑒 𝜏
𝜕𝜏
𝜕𝜃 𝜕𝐴
= 𝑃𝑒 exp(−𝑃𝑒(𝜉 − 𝐴 𝜏 )
𝜕𝜏 𝜕𝜏
𝜕𝜃
= −𝑃𝑒 exp(−𝑃𝑒(𝜉 − 𝐴 𝜏 )
𝜕𝜉

𝜕2𝜃
= 𝑃𝑒 2 exp(−𝑃𝑒(𝜉 − 𝐴 𝜏 )
𝜕𝜉 2
Nonlinear Dynamics of Laser-Processing NLD 35

The heat flux into the sheet metal needed for cutting
first the 1D-case
𝜏 ∞
Introduce the front position 𝜉 = 𝐴 𝜏 = 𝑃𝑒 𝜏
as dynamical variable

Stationary solution:
𝜃 𝜉, 𝜏 = 1 ∙ exp(−𝑃𝑒(𝜉 − 𝐴 𝜏 )

𝑎(𝑡) What are the dynamical variables?


𝐴 𝜏 =
𝑤0 𝛿 (𝑡)
Q𝜏 = 𝑤
𝑇𝑠 (𝑡) − 𝑇𝑎 0
𝜃𝑠 𝜏 =
𝑇𝑚 − 𝑇𝑎
Nonlinear Dynamics of Laser-Processing NLD 36

The heat flux into the sheet metal needed for cutting
first the 1D-case

𝜃 𝜉, 𝜏 = 1 ∙ exp(−𝑃𝑒(𝜉 − 𝐴 𝜏 )

1
Introduce 𝜃𝑠 (𝜏) 𝑎𝑛𝑑 𝑄 𝜏
𝑠𝑡𝑎𝑡 𝑃𝑒
as additional dynamical variables

Ansatz for 1D-dynamical temperature


𝜉 − 𝐴(𝜏)
𝑎(𝑡) 𝜃 𝜉, 𝜏 = 𝜃𝑠 (𝜏)exp(− )
𝐴 𝜏 = 𝑄(𝜏)
𝑤0 𝛿 (𝑡)
Q𝜏 = 𝑟
𝑇𝑠 (𝑡) − 𝑇𝑎 𝑚
𝜃𝑠 𝜏 =
𝑇𝑚 − 𝑇𝑎
Nonlinear Dynamics of Laser-Processing NLD 37

Energy balance for thermal energy


Nonlinear Dynamics of Laser-Processing NLD 38

Thermal energy content and heat flux at moving boundary

Ansatz for temperature

𝜉 − 𝐴(𝜏)
𝜃 𝜉, 𝜏 = 𝜃𝑠 (𝜏)exp(− )
𝑄(𝜏)

Thermal energy content:



𝐸 𝜏 = 𝜃 𝜉, 𝜏 𝑑𝜉 = 𝜃𝑠 (𝜏)𝑄(𝜏)
𝐴(𝜏)

Heat flux at moving boundary:


𝜕𝜃 𝜃𝑠 (𝜏)
− =
𝜕𝜉 𝜉=𝐴(𝜏)
𝑄(𝜏)
Nonlinear Dynamics of Laser-Processing NLD 39

The Stefan-Signorini condition

𝜕𝜃 𝜃𝑠 (𝜏)
− =
𝜕𝜉 𝜉=𝐴(𝜏)
𝑄(𝜏)
Nonlinear Dynamics of Laser-Processing NLD 40

Stefan-Signorini condition and Fourier‘s Law

𝜕𝜃 𝜃𝑠 (𝜏)
𝑞𝑠 = − =
𝜕𝜉 𝜉=𝐴(𝜏)
𝑄(𝜏)

Energy balance and thermal energy content


𝐸 𝜏 = 𝜃 𝜉, 𝜏 𝑑𝜉 = 𝜃𝑠 (𝜏)𝑄(𝜏)
𝐴(𝜏)
Nonlinear Dynamics of Laser-Processing NLD 41

Energy balance for thermal energy

Melting phase Heating phase


Nonlinear Dynamics of Laser-Processing NLD 42

Energy balance for thermal energy at moving boundary

Melting phase Heating phase


Nonlinear Dynamics of Laser-Processing NLD 43

Variational Formulation

3
Variational Formulation of heat conduction 𝑏1 = 5

𝑑𝑄 1 𝑑𝐴 𝑄 𝑑𝜃𝑠
= 𝑏1 − −
𝑑𝜏 𝑄 𝑑𝜏 𝜃𝑠 𝑑𝜏

In: The Theory of Materials Processing, Dowden, Schulz (eds.)


Nonlinear Dynamics of Laser-Processing NLD 44

Energy balance and Variational Formulation

𝑑𝐴 𝑑 𝜃𝑠 𝑄
𝛾𝑓 = 𝜃𝑆 + ℎ𝑚 𝑑𝜏
+ 𝑑𝜏
3
Variational Formulation of heat conduction 𝑏1 = 5
𝑑𝑄 1 𝑑𝐴 𝑄 𝑑𝜃𝑠
= 𝑏1 − −
𝑑𝜏 𝑄 𝑑𝜏 𝜃𝑠 𝑑𝜏

𝑑𝐴 𝑑𝜃𝑠
Heating phase =0 Melting phase =0
𝑑𝜏 𝑑𝜏

𝑑𝑄 1 𝑄 𝑑𝜃𝑠 𝑑𝑄 1 𝑑𝐴
= 𝑏1 − = 𝑏1 −
𝑑𝜏 𝑄 𝜃𝑠 𝑑𝜏 𝑑𝜏 𝑄 𝑑𝜏

𝜕𝜃 𝜃𝑠 (𝜏) 𝜕𝜃 1
− = − =
𝜕𝜉 𝜉=𝐴(𝜏)
𝑄(𝜏) 𝜕𝜉 𝜉=𝐴(𝜏)
𝑄(𝜏)
Nonlinear Dynamics of Laser-Processing NLD 45

The final result – Approximate Dynamical System in 1D


Nonlinear Dynamics of Laser-Processing NLD 46

The final result – Approximate Dynamical System in 1D

Ansatz
Transient solution of heating phase
heating phase melting phase

Approximate Exact
solution solution

Stationary solution of melting phase


Nonlinear Dynamics of Laser-Processing NLD 47

The final result – Approximate Dynamical System in 2D

Melting Phase
𝜃𝑠 𝜏 =1

RQ: What is remarkable considering the dynamical front radius 𝛼(𝜏)?


Nonlinear Dynamics of Laser-Processing NLD 48

The final result – Approximate Dynamical System in 2D

Melting Phase
𝜃𝑠 𝜏 =1

RQ: What is remarkable considering the dynamical front radius 𝛼(𝜏)?


RH: The dynamical front radius 𝛼(𝜏) has no effect on 𝐴 𝜏 and Q 𝜏 -- no feedback!
Nonlinear Dynamics of Laser-Processing NLD 49

Parameters of Inertial Manifold in sheet metal cutting

thermal energy
position
radius

mass flow
melt film thickness
surface temperature
Nonlinear Dynamics of Laser-Processing NLD 50

What does „approximate“ Dynamical System mean?


Nonlinear Dynamics of Laser-Processing NLD 51

What does „approximate“ Dynamical System mean?

Inertial Manifold

Time scale separation


due to presence of diffusion
Nonlinear Dynamics of Laser-Processing NLD 52

RQ: How to get the motion equations for the dynamical variables?
RH: …
Analyze the stationary solution – why?
Nonlinear Dynamics of Laser-Processing NLD 53

RQ: How to get the motion equations for the dynamical variables?
RH: …
Analyze the stationary solution – why?
 Inertial Manifold
Nonlinear Dynamics of Laser-Processing NLD 54

RQ: How to get the motion equations for the dynamical variables?
RH: …
Analyze the stationary solution – why?
 Inertial Manifold

Identify the set of variables,


which are expected to be relevant for the dynamics of the long time limit – how?
Nonlinear Dynamics of Laser-Processing NLD 55

RQ: How to get the motion equations for the dynamical variables?
RH: …
Analyze the stationary solution – why?
 Inertial Manifold contains stationary solution

Identify the set of variables,


which are expected to be relevant for the dynamics of the long time limit – how?
 Introduce time-dependence of parameters for the inertial manifold
Nonlinear Dynamics of Laser-Processing NLD 56

RQ: How to get the motion equations for the dynamical variables?
RH: …
Analyze the stationary solution – why?
 Inertial Manifold

Identify the set of variables,


which are expected to be relevant for the dynamics of the long time limit – how?
 Introduce time-dependence of parameters for the inertial manifold

Find motion equations for the set of variables – how?


Nonlinear Dynamics of Laser-Processing NLD 57

RQ: How to get the motion equations for the dynamical variables?
RH: …
Analyze the stationary solution – why?
 Inertial Manifold

Identify the set of variables,


which are expected to be relevant for the dynamics of the long time limit – how?
 Introduce time-dependence of parameters for the inertial manifold
 Corrections by parameters with faster relaxation

Find motion equations for the set of variables – how?


Nonlinear Dynamics of Laser-Processing NLD 58

RQ: How to get the motion equations for the dynamical variables?
RH: …
Analyze the stationary solution – why?
 Inertial Manifold

Identify the set of variables,


which are expected to be relevant for the dynamics of the long time limit – how?
 Introduce time-dependence of parameters for the inertial manifold

Find motion equations for the set of variables – how?


 Find an Ansatz for the temperature.
 Derive the heat flux necessary for moving the cutting front.
Nonlinear Dynamics of Laser-Processing NLD 59

Temperature in the sheet metal


and
heat flux into the sheet metal
needed for cutting
Nonlinear Dynamics of Laser-Processing NLD 60

The result – stationary temperature in the sheet metal

𝑇𝑠 (𝑡) − 𝑇𝑎
𝜃𝑠 𝜏 =
𝑇𝑚 − 𝑇𝑎

Why 𝑎(𝑡)
𝐴 𝜏 =
the front position 𝑎(𝑡) does not enter? 𝑤0
𝛿 (𝑡)
Q 𝜏 = 𝑤0
𝑟𝑚 (𝑡)
𝛼 𝜏 =
𝑤0
Nonlinear Dynamics of Laser-Processing NLD 61

The result – stationary temperature in the sheet metal

𝑇𝑠 (𝑡) − 𝑇𝑎
𝜃𝑠 𝜏 =
𝑇𝑚 − 𝑇𝑎

Why 𝑎(𝑡)
𝐴 𝜏 =
the beam radius is chosen 𝑤0
as scale for feeding direction? 𝛿 (𝑡)
Q 𝜏 = 𝑤0
𝑟𝑚 (𝑡)
𝛼 𝜏 =
𝑤0
Nonlinear Dynamics of Laser-Processing NLD 62

The scaled radius 𝜶 of the cutting front

𝑇𝑠 (𝑡) − 𝑇𝑎
𝜃𝑠 𝜏 =
𝑇𝑚 − 𝑇𝑎
𝑎(𝑡)
𝐴 𝜏 =
𝑤0
𝛿 (𝑡)
Q 𝜏 = 𝑤0
𝑟𝑚 (𝑡)
𝛼 𝜏 =
𝑤0
Nonlinear Dynamics of Laser-Processing NLD 63

The exact solution and it‘s approximation – Emulator


The temperature of a
moving cylinder as heat source

can be decomposed

𝑆 𝜌, 𝜑 = 𝑐𝑜𝑛𝑠𝑡.
becomes nearly circles
for large Pe-number
displaced by
Nonlinear Dynamics of Laser-Processing NLD 64

The exact solution and it‘s approximation – Emulator


The temperature of a
moving cylinder as heat source

can be decomposed

𝑆 𝜌, 𝜑 = 𝑐𝑜𝑛𝑠𝑡.
become nearly circles
for large Pe-number
displaced by
Nonlinear Dynamics of Laser-Processing NLD 65

Introduce the penetration depth of heat


as dynamical variable

𝜅 𝑤0
𝛿 = , 𝑃𝑒 =
𝑣0 𝛿

𝛿 𝜏 1
𝑄 𝜏 ≔
𝑤0 𝑠𝑡𝑎𝑡𝑖𝑛𝑜𝑟𝑦 𝑃𝑒

𝑇𝑠 (𝑡) − 𝑇𝑎
𝜃𝑠 𝜏 =
𝑇𝑚 − 𝑇𝑎
𝑎(𝑡)
𝐴 𝜏 =
𝑤0
𝛿 (𝑡)
Q 𝜏 = 𝑤0
𝑟𝑚 (𝑡)
𝛼 𝜏 =
𝑤0
Nonlinear Dynamics of Laser-Processing NLD 66

Lecture 6
Nonlinear Dynamics of Laser-Processing NLD 67

The result – scaled temperature in the sheet metal


Nonlinear Dynamics of Laser-Processing NLD 68

The result – scaled temperature in the sheet metal

𝑇𝑠 (𝑡) − 𝑇𝑎
𝜃𝑠 𝜏 =
𝑇𝑚 − 𝑇𝑎
𝑎(𝑡)
𝐴 𝜏 =
𝑤0
𝛿 (𝑡)
Q 𝜏 = 𝑤0
𝑟𝑚 (𝑡)
𝛼 𝜏 =
𝑤0
Nonlinear Dynamics of Laser-Processing NLD 69

The function 𝜷[𝑸 𝜶]


Nonlinear Dynamics of Laser-Processing NLD 70

The function 𝜷[𝑸 𝜶]


Nonlinear Dynamics of Laser-Processing NLD 71

Interpretation of the Ansatz for the temperature

What is the exact temperature for the 1D-case?

 RH:

What is the approximate temperature for large radius of the cutting front?

 RH:
Nonlinear Dynamics of Laser-Processing NLD 72

Interpretation of the Ansatz for the temperature

What is the exact temperature for the 1D-case?

 RH:

What is the approximate temperature for large radius of the cutting front?

 RH:
Nonlinear Dynamics of Laser-Processing NLD 73

Interpretation of the Ansatz for the temperature

What is the exact temperature for the 1D-case?

 RH:

What is the approximate temperature for large radius 𝛼 of the cutting front?

 RH:
Nonlinear Dynamics of Laser-Processing NLD 74

Interpretation of the Ansatz for the temperature

What is the approximate temperature for large radius of the cutting front?

 We get the one-dimensional solution.


Nonlinear Dynamics of Laser-Processing NLD 75

Summary and Analysis


Nonlinear Dynamics of Laser-Processing NLD 76

The heat flux into the sheet metal needed for cutting

Stefan-Signorini- Condition
𝐴 𝑺 − 𝒒𝜆 ∙ −𝒏 = 𝜌𝐻𝑚 𝑣𝑏

𝒒𝜆 ∙ −𝒏 = −𝜆 𝜵𝑇 ∙ −𝒏

Ansatz from heat conduction?


Nonlinear Dynamics of Laser-Processing NLD 77

The heat flux into the sheet metal needed for cutting
first the 1D-case
scaling

Buckingham
Nonlinear Dynamics of Laser-Processing NLD 78

The heat flux into the sheet metal needed for cutting
first the 1D-case
𝜏 ∞
Introduce the front position 𝜉 = 𝐴 𝜏 = 𝑃𝑒 𝜏

𝜃 𝜉, 𝜏 = 1 ∙ exp(−𝑃𝑒(𝜉 − 𝐴 𝜏 )

What are the dynamical variables?


𝑎(𝑡)
𝐴 𝜏 =
𝑤0 𝛿 (𝑡)
Q𝜏 = 𝑤
𝑇𝑠 (𝑡) − 𝑇𝑎 0
𝜃𝑠 𝜏 =
𝑇𝑚 − 𝑇𝑎
Nonlinear Dynamics of Laser-Processing NLD 79

The heat flux into the sheet metal needed for cutting
first the 1D-case

𝜃 𝜉, 𝜏 = 1 ∙ exp(−𝑃𝑒(𝜉 − 𝐴 𝜏 )

1
Introduce 𝜃𝑠 (𝜏) 𝑎𝑛𝑑 𝑄 𝜏
𝑠𝑡𝑎𝑡 𝑃𝑒

𝜉 − 𝐴(𝜏)
𝜃 𝜉, 𝜏 = 𝜃𝑠 (𝜏)exp(− )
𝑄(𝜏)
𝑎(𝑡) Ansatz for 1D-dynamical temperature
𝐴 𝜏 =
𝑤0 𝛿 (𝑡)
Q𝜏 = 𝑟
𝑇𝑠 (𝑡) − 𝑇𝑎 𝑚
𝜃𝑠 𝜏 =
𝑇𝑚 − 𝑇𝑎
Nonlinear Dynamics of Laser-Processing NLD 80

Motion equations for the 1D-dynamical variables

𝑇𝑠 (𝑡) − 𝑇𝑎 𝑎(𝑡)
𝜃𝑠 𝜏 = 𝐴 𝜏 =
𝑇𝑚 − 𝑇𝑎 𝑤0

𝛿 (𝑡) 𝛿 (𝑡)
Q𝜏 = 𝑟𝑚
Q𝜏 = 𝑟𝑚
Nonlinear Dynamics of Laser-Processing NLD 81

Changing of boundary conditions


Nonlinear Dynamics of Laser-Processing NLD 82

Time scale separation also within the Inertial Manifold


Nonlinear Dynamics of Laser-Processing NLD 83

Fast and slow movement of the front reflect ripple shape

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