LASER BLIND POCKET MILLING

Submitted to : Dr. Janakarajan Ramkumar

Group Members : Mayank Patel Ram Kishor Singh
18205404 18205011
 CONTENTS

• INTRODUCTION
• OBJECTIVE
• LITERATURE REVIEW
• EXPERIMENTATION AND MEASUREMENTS
• RESULTS AND DISCUSSION
• CONCLUSION
• FUTURE SCOPE
• REFERENCES
 INTRODUCTION

• Laser milling is a process for direct material removal in a layer-by-layer

fashion to make a blind slot.

• In ‘blind 'milling the depth is not a set parameter but a critical variable
which depends upon material properties, cutting power and speed.

• High absorptivity generally leads to high manufacturing throughput.

• The shorter the wavelength, the better the light absorptivity for metal.

• The higher the wavelength, the better the light absorptivity for polymer.
 OBJECTIVE

The present work has been show to investigate blind pocket micro-milling
(Raster mode) performance on two different material titanium as a low
conducting metal and acrylic as a polymer, with different parameters, namely
laser power, cutting speed and number of scan and compare experimental
values with theoretical one.
 LITERATURE REVIEW

• The investigation shown by Saklakoglu and Kasman [1] was focused on

micro-milling performance of the AISI H13 using 30-W fiber laser. Their
work involved the effect of laser power, scan speed, frequency and fill
spacing on surface roughness and milling depth during multi-pass
operation. The second-order regression model was proposed to predict
milling depth and surface roughness.

• Snakenborg et al.[2] had reported a use of commercial CO2 laser for

fabrication of micro-fluidic systems in polymers.
 EXPERIMENTATION AND MEASUREMENTS

• Work piece materials: In metal category titanium is used because of its

low conductivity (21.9 W/ (m- K)) so laser can easily work without
conductive loss of heat. In polymer, transparent acrylic is used which has
conductivity (0.2 W/ (m-K)).

• Laser source: 18 W CO2 pulse laser for better machining in polymer

because of light absorption has directly proportional relation with the
wavelength (10.6 𝜇𝑚)of laser[3]. 30 W fiber laser used for metal because
of light absorption has inversely proportional to the wavelength (1.07 𝜇𝑚)
of incident laser.

• Parameter variation: Study of change of percentage value of power

capacity(90%,70%,50%,30%) of laser and number of pass(1,3) at a certain
specific speed(10%,30%,50%) on the depth and surface roughness
variation for titanium.
• Design of blind pocket
• Equipments used for measurement:

Design of blind
1. Vernier caliper-For depth measurement pocket(10*10mm2
2. Optical microscope-For micro level images and 5*5mm2)
3. Mechanical Profilometer-For roughness of milled surface

70%,3,inner 70%,3,outer 90%,3,inner 90%,3,outer

acrylic acrylic metal metal
 RESULTS AND DISCUSSION

Roughness
Table For metal: Titanium
Power Factor Velocity Factor Number 𝑅𝑎 (𝜇𝑚) 𝑅𝑧 (𝜇𝑚) 𝑅𝑞 (𝜇𝑚)
of scan

90% 10% 3 5.33 31.41 6.75

90% 10% 1 1.85 11.00 2.32
70% 10% 3 8.54 45.75 10.50
70% 10% 1 7.87 44.25 9.73

Acrylic along 𝑅𝑎 (𝜇𝑚) 𝑅𝑧 (𝜇𝑚) 𝑅𝑞 (𝜇𝑚)

Normal surface cross length
𝑅𝑎 (𝜇𝑚) 𝑅𝑧 (𝜇𝑚) 𝑅𝑞 (𝜇𝑚)
direction on metal

0.16 1.60 0.24

0.02 0.13 0.02
 Effect of parameters on Pocket depth
Power variation at 10% velocity
% of Exp. 1 pass (mm) 𝟐∗𝐧∗𝛂∗𝐏 Exp. 3 pass (mm)
Pmax 𝐝=
𝛑 ∗ 𝐐𝐯 ∗ 𝐃 ∗ 𝐕
(18W)
1 pass E (%) 3pass E (%)
90 0.37 0.39 0.40 0.5276 36.43 1.583 59.43 0.99 1.01 0.98

0.3867 0.993
70 0.34 0.35 0.36 0.4104 17.25 1.2313 26.06 0.98 0.97 0.98

0.35 0.9767
50 0.17 0.19 0.2 0.293 56.93 0.879 59.81 0.55 0.56 0.54

0.1867 0.55
30 0.09 0.11 0.12 0.1758 64.76 0.5276 93.04 0.27 0.27 0.28

0.1067 0.2733

Velocity variation at 90% power

% of Vmax 1 pass (mm) 𝟐∗𝐧∗𝛂∗𝐏 dexp −dthe
(90%Pmax) 𝐝= Error(E)=
𝛑 ∗ 𝐐𝐯 ∗ 𝐃 ∗ 𝐕 dexp

10 0.37 0.39 0.40 0.5276 36.43

0.3867
30 0.20 0.22 0.23 0.1758 18.58
0.216
50 0.056 0.056 0.055 0.10562 33.926
0.1597
Plots of depth for Acrylic

Variation of power vs depth at

10%vel Variation of velocity vs
depth at 90%power
 Roughness plots for metals

Normal surface cross direction

power 90% and 3 pass

power 90% and 1 pass

 power 70% and 3 pass

power 70% and 1 pass

 CONCLUSION

1. Light absorptivity of Acrylic is proportional to the wavelength of laser

source, whereas metal has inverse nature.
2. Results show that the increase in depth does inversely vary with cutting
speed, whereas depth does vary linearly with cutting power.
3. After processing of milling it erodes the surface quality and quality of
surface directly vary with increasing the power and quality inversely with
number of pass.
4. In experiment with variation of parameter error vary from 17.25 to 93.04
depending on assumption made in theoretical analysis like no conduction and
radiation loss, homogeneous material etc.
5. Error should be min while critical point of power and velocity supplied.
 FUTURE SCOPE

Facing the significant variation between predicted values and experimental

one is more common, so one can try to produce some mathematical
modeling and come up with a algorithm which provide more accurate
prediction of data.
 REFERENCES

1. Investigation of micro-milling process parameters for surface roughness and

milling depth. Saklakoglu IE, Kasman S (2011) Int J Adv Manuf Technol 54:567–
578

2. Microstructure fabrication with a CO2 laser system. Snakenborg D, Klank H,

Kutter JP (2004) J Micromech Microeng 14:182–189

3. Prediction of depth of cut for single-pass laser micro-milling. Chinmay K. Desai

& Abdulhafiz Shaikh. s.l. : springer, 2012, Int J Adv Manuf Technol, Vol. 60, pp.
865–882.

4. Prediction of poly-methyl-methacrylate laser milling process characteristics.

Doriana M. D’Addonaa, Silvio Gennab, Claudio Leonea, Davide Matarazzoa. s.l. :
Elsevier, 2016, CIRP, Vols. 41 ,981 – 986.