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RESEARCH PAPERS

Process-Efficiency Prediction in High Power Diode Laser Forming

[+] Author and Article Information
L. Casamichele, V. Tagliaferri

Department of Mechanical Engineering, University of Rome “Tor Vergata,” Via del Politecnico 1, Rome 00133, Italy

F. Quadrini

Department of Mechanical Engineering, University of Rome “Tor Vergata,” Via del Politecnico 1, Rome 00133, Italyfabrizio.quadrini@uniroma2.it

J. Manuf. Sci. Eng 129(5), 868-873 (Jan 31, 2007) (6 pages) doi:10.1115/1.2738124 History: Received July 13, 2006; Revised January 31, 2007

The present work is an experimental investigation on the laser forming process of aluminum alloy and stainless-steel thin sheets. A high-power diode laser (HPDL) with a nonsymmetric spot configuration was employed at medium and low scanning rates. The tests were performed at different operating conditions: scanning rate, laser spot orientation, and laser beam power. The experimental results revealed the great influence of the laser spot orientation on the total bending angle and the harmful effect of the surface melting during heating. Spot orientation significantly affects the treated area extension during laser scanning. Employing an analytical thermo-mechanical model, a dimensionless processing map can be presented that allows the prediction of the sheet bending angle depending on the material properties and machining parameters. Dimensional terms of the processing map can be associated to efficiency terms for heat transfer and bending.

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Copyright © 2007 by American Society of Mechanical Engineers
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Figures

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Figure 1

Experimental configuration for HPDL sheet forming

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Figure 2

Total bending angle as a function of pass number for stainless-steel samples at different laser power and scanning rates (90deg spot orientation)

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Figure 3

Total bending angle as a function of pass number for aluminum alloy samples at different laser power and scanning rates (90deg spot orientation)

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Figure 4

Total bending angle as a function of pass number for stainless-steel samples at different laser power and scanning rates but equal energy amount per unit length (90deg spot orientation)

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Figure 5

Total bending angle as a function of pass number for stainless-steel and aluminum samples at 450W laser power and 7.5mm∕s scanning rate (90deg spot orientation)

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Figure 6

Total bending angle as a function of pass number for stainless steel, with (upper curve) and without (lower curve) surface melting (90deg spot orientation)

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Figure 7

Total bending angle as a function of pass number for stainless steel at different laser power and spot orientations (4.5mm∕s laser scanning rate)

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Figure 8

Total bending angle as a function of pass number for stainless steel at different spot orientations (700W laser power, 7.5mm∕s laser scanning rate)

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Figure 9

Total bending angle as a function of pass number for stainless steel at different spot orientations (700W laser power, 7.5mm∕s laser scanning rate)

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Figure 10

Bending angle after a single laser pass as a function of laser power for stainless steel at different laser scanning rates (90deg spot orientation)

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Figure 11

Laser bending process map for all the experimental conditions and materials

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Figure 12

Laser bending process map for stainless steel in all the experimental conditions

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