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Modelling,
Model Reduction
and
Simulation
of Laser Processing
© Fraunhofer ILT
Nonlinear Dynamics of Laser-Processing NLD 2
Image
courtesy of Siemens
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.
Digitized enrichment
2. Mathematical Model Reduction
„ Digital Guess“
of sparse data
• Asymptotic Analysis
Applicability
Strength
• Singular Perturbation
• „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
20 µm 80 µm 200 µm 8 mm length
2 µs 100 µs 1 ms time
Ripple pattern
changing with
modulation frequency
of laser power
Nonlinear Dynamics of Laser-Processing NLD 10
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
𝜕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
Lengths: 𝛿 Velocities:
Convection-diffusion-equation with external sources
Length scales:
Time scales:
Nonlinear Dynamics of Laser-Processing NLD 13
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
𝑄(𝜏)
Depth
With courtesy of
Fraunhofer ILT, Thomas Molitor
Nonlinear Dynamics of Laser-Processing NLD 17
Parameters:
𝜕𝜃 𝜕 2 𝜃
= , 𝜉 ∈ [𝐴 𝜏 , +∞)
𝜕𝜏 𝜕𝜉 2
𝜕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
Non-linear integral equation and ordinary differential equation for melting phase
Nonlinear Dynamics of Laser-Processing NLD 21
Contents
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
𝒂(𝒕) 𝒓𝒎 (𝒕)
𝑨 𝝉 = 𝜶 𝝉 =
𝒘𝟎 𝒘𝟎
𝑻𝒔 (𝒕) − 𝑻𝒂 𝜹 (𝒕)
𝜽𝒔 𝝉 = Q𝝉 = 𝒓𝒎
𝑻𝒎 − 𝑻𝒂
𝒂(𝒕) 𝒓𝒎 (𝒕)
𝑨 𝝉 = 𝜶 𝝉 =
𝒘𝟎 𝒘𝟎
𝑻𝒔 (𝒕) − 𝑻𝒂 𝜹 (𝒕)
𝜽𝒔 𝝉 = Q𝝉 = 𝒓𝒎
𝑻𝒎 − 𝑻𝒂
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
The heat flux into the sheet metal needed for cutting
first the 1D-case
scaling
𝜅 𝜆 𝑇𝑚 − 𝑇𝑎
𝑤0,𝑠𝑐𝑎𝑙𝑒 =𝛿= , 𝑞𝑠𝑐𝑎𝑙𝑒 =
𝑣0 𝑤0
Nonlinear Dynamics of Laser-Processing NLD 32
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 )
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 )
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
𝜉 − 𝐴(𝜏)
𝜃 𝜉, 𝜏 = 𝜃𝑠 (𝜏)exp(− )
𝑄(𝜏)
𝜕𝜃 𝜃𝑠 (𝜏)
− =
𝜕𝜉 𝜉=𝐴(𝜏)
𝑄(𝜏)
Nonlinear Dynamics of Laser-Processing NLD 40
𝜕𝜃 𝜃𝑠 (𝜏)
𝑞𝑠 = − =
𝜕𝜉 𝜉=𝐴(𝜏)
𝑄(𝜏)
∞
𝐸 𝜏 = 𝜃 𝜉, 𝜏 𝑑𝜉 = 𝜃𝑠 (𝜏)𝑄(𝜏)
𝐴(𝜏)
Nonlinear Dynamics of Laser-Processing NLD 41
Variational Formulation
3
Variational Formulation of heat conduction 𝑏1 = 5
𝑑𝑄 1 𝑑𝐴 𝑄 𝑑𝜃𝑠
= 𝑏1 − −
𝑑𝜏 𝑄 𝑑𝜏 𝜃𝑠 𝑑𝜏
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
Ansatz
Transient solution of heating phase
heating phase melting phase
Approximate Exact
solution solution
Melting Phase
𝜃𝑠 𝜏 =1
Melting Phase
𝜃𝑠 𝜏 =1
thermal energy
position
radius
mass flow
melt film thickness
surface temperature
Nonlinear Dynamics of Laser-Processing NLD 50
Inertial Manifold
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
RQ: How to get the motion equations for the dynamical variables?
RH: …
Analyze the stationary solution – why?
Inertial Manifold contains stationary solution
RQ: How to get the motion equations for the dynamical variables?
RH: …
Analyze the stationary solution – why?
Inertial Manifold
RQ: How to get the motion equations for the dynamical variables?
RH: …
Analyze the stationary solution – why?
Inertial Manifold
RQ: How to get the motion equations for the dynamical variables?
RH: …
Analyze the stationary solution – why?
Inertial Manifold
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
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
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
can be decomposed
𝑆 𝜌, 𝜑 = 𝑐𝑜𝑛𝑠𝑡.
becomes nearly circles
for large Pe-number
displaced by
Nonlinear Dynamics of Laser-Processing NLD 64
can be decomposed
𝑆 𝜌, 𝜑 = 𝑐𝑜𝑛𝑠𝑡.
become nearly circles
for large Pe-number
displaced by
Nonlinear Dynamics of Laser-Processing NLD 65
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
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
RH:
What is the approximate temperature for large radius of the cutting front?
RH:
Nonlinear Dynamics of Laser-Processing NLD 72
RH:
What is the approximate temperature for large radius of the cutting front?
RH:
Nonlinear Dynamics of Laser-Processing NLD 73
RH:
What is the approximate temperature for large radius 𝛼 of the cutting front?
RH:
Nonlinear Dynamics of Laser-Processing NLD 74
What is the approximate temperature for large radius of the cutting front?
The heat flux into the sheet metal needed for cutting
Stefan-Signorini- Condition
𝐴 𝑺 − 𝒒𝜆 ∙ −𝒏 = 𝜌𝐻𝑚 𝑣𝑏
𝒒𝜆 ∙ −𝒏 = −𝜆 𝜵𝑇 ∙ −𝒏
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 )
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
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