Simulation and prediction in laser bending of silicon sheet

The laser bending of single-crystal silicon sheet (0.2 mm in thickness) was investigated with JK701 Nd:YAG laser. The models were developed to describe the beam characteristics of pulsed laser. In order to simulate the process of laser bending, the FEM software ANSYS was used to predict the heat temperature and stress-strain fields. The periodic transformation of temperature field and stress-strain distribution was analyzed during pulsed laser scanning silicon sheet. The results indicate that the mechanism of pulsed laser bending silicon is a hybrid mechanism in silicon bending, rather than a simple mechanism of TGM or BM. This work also gets silicon sheet bent after scanning 6 times with pulsed laser, and its bending angle is up to 6.5°. The simulation and prediction results reach well agreement with the verifying experiments.     

NUMERICAL INVESTIGATION OF STRAIGHT-LINE LASER FORMING UNDER THE TEMPERATURE GRADIENT MECHANISM

Laser forraing is a new flexible and dieless forming technique. To achieve the high accuracy forming, the temperature gradient mechanism （TGM） is studied. In the analysis of TGM, the plate bends about x-axis and about y-axis as well. To understand the deformation trend, the numerical simulation of deformation of plate is conducted by choosing different laser powers, laser spot diameters, scanning speeds, lengths, widths and thicknesses. From the results of simulation, it can be seen that the laser spot diameter, the scanning speed, laser power and thickness of plate play dominant roles in the laser forming process. However, the bending angles αx and αy show different trends with the variation of parameters. In addition, in comparison with above four parameters, the effect of length and width of plate on the beading angle may be neglected, but their effects are significant for the bending radius R.     

A study on laser bending of tailor machined blanks with various irradiating schemes

In this work, laser bending of tailor machined blanks has been investigated, both experimentally and numerically. Due to thickness variations in tailor machined blanks, laser bending of these blanks is more complicated than monolithic plates. In these blanks, bending angles and curvatures are different in various sections. Also, multi-curvature bending phenomenon in other words, non-uniform bending in the transverse direction can appear more seriously in tailor machined blanks than monolithic plates. In this paper, a study on laser bending of tailor machined blanks with various irradiating schemes has been performed. For this purpose, three different irradiating schemes i.e. variable speed method (VSM), variable power method (VPM) and variable beam diameter method (VBDM) have been considered. In each method, relevant variable parameter was changed in various sections of tailor machined blank. The results show that using these irradiating methods can reduce differences in bending angles and curvatures of two sections in tailor machined blanks. However, the results show that for the cases investigated in this paper, VSM is a better irradiating scheme than VPM and VBDM. After VSM, the VPM is a suitable choice. It is also concluded that for investigated conditions, VBDM is not a suitable method for laser bending of tailor machined blanks in comparison with VPM and VSM. In other words the results of bending angles and curvature uniformities are not satisfactory with VBDM.     

Characterization of the residual strains in iterative laser forming

In laser forming, thermally induced strains transverse to the laser scan line vary with depth in the material and contribute most significantly to the desired deformation. The through-thickness transverse residual strain distribution was measured by neutron diffraction in laser-formed low carbon steel and aluminium alloy specimens. The specimens were formed with a wide range of laser line energies covering the temperature gradient mechanism (TGM) and shortening or upsetting mechanism (SM), and for single and multi-pass forming (up to 3 laser passes). Below the saturation line energy where the TGM dominates, the gradient of the through-thickness strain distribution was found to increase with increasing line energy and number of laser passes; the gradient decreased again at line energies above the saturation line energy where the efficiency of the TGM decreases. Iterative laser forming can be applied to reduce weld-induced distortions. The peak longitudinal strain measured in the weld seam of a specimen that had been straightened by iterative laser forming was also significantly reduced.     

微形电机机壳16工步连续级进弯曲模结构设计

针对微形电机机壳采用板料卷圆生产的工艺要求,设计了一种7工位连续冲裁、6工位连续弯曲冲裁、单工位落料的16工步的360°卷圆成形连续级进模。模具整体工序包括连续冲裁、连续弯曲冲裁和冲裁落料3道工序。针对壳件的成形特征,采用1个工位冲出定位孔,6个工位对壳体上的9个特征进行连续冲裁成形及倒角成形;针对壳件的弯曲成形,采用6个工位对冲裁壳体进行连续弯曲成形,工步中设置了3个弯曲成形机构,分别为仿形凹模机构、楔紧块驱动的双侧滑块挤压弯曲机构及接口压入成形机构,来实现壳件的360°卷圆成形;为保证后续弯曲工步载料及内圆成形,将内圆成形件设计成一种可以跟随弯曲凹模做小距离的向上浮动的成形构件。最终成形的壳件由单冲头落料,并由气缸驱动的接件圆柱进行接料转移。模具结构整体布局设计简单合理,机构设置巧妙,可为同类壳件的生产提供有益借鉴。     

Experimental and numerical modeling of buckling instability of laser sheet forming

New experimental results show that laser bending can be extended to generate a bending angle not only towards but also away from the laser beam, giving more flexibility to the process. In order to explain this buckling instability, a series of experiments have been carried out with real-time measurement of the bending angle for different materials, thicknesses, scanning speeds, laser beam diameters and laser powers, pre-bending conditions, and cooling conditions. Furthermore, a 3-D FEM simulation has been performed that includes a non-linear, transient, indirect coupled, thermal–structural analysis accounting for the nonlinear geometric and material properties. The buckling deformation, bending angle and distribution of stress–strain and temperature, as well as residual stresses, have been obtained from the simulations. The bending angle is affected by the temperature distribution and gradient, the mechanical and thermal properties of the sheet metal material, and the process parameters, such as the laser power, the laser beam diameter, the scanning speed, the material, the sample geometry, and other bending conditions. The buckling mechanism can be illustrated by the simulation results.     

Numerical investigation on the laser bending of stainless steel foil with pre-stresses

In this paper, a new laser bending process of stainless steel foils with applied pre-stresses is presented. Three different loading models are analyzed. The desired pre-stress distribution in the heated zone of the stainless steel foil is obtained. Using the thermal elastic–plastic finite element method (FEM), the 3D thermal–mechanical FEM models of laser bending process with various pre-stresses are developed and the forming mechanism is analyzed. The simulation results show that under buckling mechanism, the deformation of the stainless steel foil depends on the integration of the thermal stress and the pre-stress when the laser beam irradiates the foil. The forming performance can be improved significantly under pre-stress, and the deformation direction can also be controlled easily by changing the direction and value of the pre-loading. The bending angles of the stainless foils increase remarkably with the increase of the pre-loading, and both are almost in linear relationship.     

氧化钒薄膜脉冲激光损伤研究

采用离子束溅射和退火工艺,在K9玻璃基体上制备了氧化钒薄膜,并对其微观形貌及组成进行了研究,还应用脉宽10ns、532nm波长的Nd:YAG激光器对薄膜样品进行了激光损伤阈值的测试.扫描电镜(SEM)分析结果表明,所制备的氧化钒薄膜均匀致密,晶粒平均尺寸约50nm.X射线光电子谱(XPS)分析可知,薄膜中钒的价态为 4价和 5价,薄膜由VO2和V2O5组成.在1Hz多次单点照射的条件下,以刚可见损伤作为判断激光损伤阈值的条件,得到此氧化钒薄膜的激光损伤阈值为21.9mJ/cm2.对刚可见损伤光斑和明显损伤光斑进行了微观分析,探讨了激光损伤原因.     

薄板激光弯曲机理的研究

试件在激光与材料非熔凝作用下动态变形过程实时测量的结果表明：薄板在激光照射下所引起最终变形的方向取决于材料的性质，可能是朝向激光束或背向激光束。研究结果进一步完善了薄板激光弯曲的变形机理，并为研究薄板激光弯曲过程奠定了基础。     

激光加热弯曲成型技术

板材激光加热弯曲成形是近年来提出的一种先进的零件成形方法。通过对金属板材激光加热弯曲成型的特点分析,探讨了激光加热弯曲成型的机理,同时对这一技术的发展现状作了归纳并对其发展进行了展望。     

锁杆导向架复合模设计

介绍了锁杆导向架成形工艺及模具设计,详细介绍了落料、弯曲和冲关节形长孔等机构的设计。实践证明,复合模满足了产品设计的要求,对类似结构产品的模具设计具有借鉴作用。     

激光弯曲工艺中板材厚度的影响规律

用大变形弹塑性有限元法对金属板材柔性成形新工艺———激光弯曲进行了动态数值模拟。从热学及热力学的观点出发,阐明了该工艺的变形机理,建立了弯曲过程中的应力模型;论证了板料厚度对温度梯度和弯曲角度的影响,提出了能够实现激光弯曲工艺的最小相对光束半径的新概念,为该工艺进一步深入研究奠定了基础。模拟结果与试验吻合较好。     

Simulation and prediction in laser bending of silicon sheet

The laser bending of single-crystal silicon sheet (0.2 mm in thickness) was investigated with JK701 Nd:YAG laser. The models were developed to describe the beam characteristics of pulsed laser. In order to simulate the process of laser bending, the FEM software ANSYS was used to predict the heat temperature and stress-strain fields. The periodic transformation of temperature field and stress-strain distribution was analyzed during pulsed laser scanning silicon sheet. The results indicate that the mechanism of pulsed laser bending silicon is a hybrid mechanism in silicon bending, rather than a simple mechanism of TGM or BM. This work also gets silicon sheet bent after scanning 6 times with pulsed laser, and its bending angle is up to 6.5o. The simulation and prediction results reach well agreement with the verifying experiments.     

船舶钢板激光弯曲成形的实验研究

在对船舶钢板激光弯曲成形过程进行实验研究中，采用CO2激光器研究了激光功率、扫描速度、扫描次数以及钢板厚度对船舶钢板激光弯曲成形的影响规律。实验中实时测量了船舶钢板激光弯曲成形过程钢板弯曲角度和温度的变化。结果表明：钢板弯曲角度随激光功率的增加而增加，随激光束扫描速度的增加而减小，而且随着钢板厚度的增加，弯曲角度减小；激光工艺参数和钢板厚度都对钢板激光多次扫描成形产生影响，钢板的弯曲角度随着激光扫描次数的增加而增加。对于较薄的船舶钢板，钢板弯曲角度随扫描次数增加近似呈线性增加，而较厚的钢板，随扫描次数的增加，钢板弯曲角度的增加逐渐减小。     

Spatter-free laser percussion drilling of closely spaced array holes

Spatter is one of the inherent defects commonly associated with holes produced with laser drilling. This work reports on a method of spatter prevention, workable for a wide range of process parameters. The method is based on the application of a specially developed anti-spatter composite coating (ASCC), containing a mixture of ceramic filler particles embedded in a silicone elastomer matrix, on the workpiece surface prior to laser percussion drilling. Experiments were conducted using a fibre-optic delivered 400 W Nd:YAG laser for the drilling of closely spaced through holes (2 mm hole pitch) in Nimonic 263 alloy sheets. The work revealed that the ASCC effectively prevented the deposition of spatter such that laser drilled holes were produced whilst maintaining the as-received surface characteristics of the Nimonic 263 alloy for all the assist gases tested (O₂, air, N₂ and Ar). The process characteristics and spatter prevention mechanism associated with the use of the ASCC have been investigated using optical microscopy, scanning electron microscopy (SEM), energy dispersive X-ray (EDX) analysis, contact angle analysis and high-speed photographic imaging. Comparative studies were also made with the case of uncoated laser drilling.     

耐热不锈钢板材激光弯曲成形温度场有限元分析

通过建立激光板料弯曲三维热力耦合模型,对1Cr17Ni2耐热不锈钢板材在激光弯曲成形过程中温度场进行了有限元模拟,研究了板料上下表面的温度随时间的变化规律,研究结果表明1Cr17Ni2不锈钢板材的成形机理符合温度梯度机理.     

Laser micro-bending process based on the characteristic of the laser polarization

The laser polarization is a basic characteristic of CO₂ and solid-state lasers. The material's absorptivity to laser is dependent upon the laser incident angle. Thus, the laser polarization can be utilized to control the bending angle by changing the laser incident angle during laser bending. The laser polarization is introduced into laser micro-bending, and an experimental system is established. Laser micro-bending process based on the characteristic of the laser polarization is realized. For uncoated stainless steel specimen, the bending angles acquired at bigger incident angles are bigger than those acquired at zero incident angles. The bending angles increase linearly with the increase of the incident angle when the incident angle changes from 60° to 80°. During laser multi-scan bending, the final bending angle no longer varies with the scanning number, and approximately equals to the complement angle of the incident angle when it approaches to the complement angle. By means of adjusting the laser incident angle and scanning velocity, unfinished and finishing laser bending can be realized to satisfy the forming efficiency and accuracy. The absolute error between the final bending angle and the expected angle is less than 0.1°.     

钛合金板料激光曲线弯曲及热辐射对其组织性能的影响

研究了激光能量密度、路径曲率和扫描次数对TC4（Ti－6Al-4V）板料弯曲变形的影响规律,同时,分析了热辐射对板料显微组织和表面硬度的影响。结果表明：（1）存在一个最的能量密度值使板料一次弯曲所获得的的弯曲角度达到峰值;（2）随路径曲率的增加,弯曲角度减小;（3）第一次扫描以后的扫描次数与弯曲角度呈准线性关系。（4）合适的工艺参数不会导致材料显微组织变化,且激光热辐射对材料表面有淬火效应,使加热区材料表面硬度均有所提高。     

铜合金薄板的脉冲激光弯曲成形数值分析与实验

借助有限元方法研究C194铜合金薄板的脉冲激光弯曲成形。建立脉冲激光弯曲成形的热力耦合分析模型,解决了激光热源加载、求解稳定性和精度控制等关键技术;对多点脉冲激光弯曲成形进行有限元模拟,通过对模型的温度场、应力/应变场和位移场的动态变化和稳态分布的分析,揭示了其成形机理和规律,薄板的整体弯曲成形是所有脉冲变形效应的叠加结果,且变形量与脉冲次数有着明显的线性关系。实验结果表明,数值分析结果与实验结果有较好的一致性。     

管材激光弯曲工艺研究

管材激光弯曲是一种具有极高柔性的金属塑性加工方法,特别适合于薄壁管材的小曲率半径弯曲。文章依据塑性力学原理推导了管材激光弯曲的弯曲角度计算公式,并与试验结果进行了对比。理论计算与试验结果均表明,激光弯曲角度随激光扫描次数的增加而增大,但并不呈线性关系,同时还存在一个获得永久塑性弯曲的激光功率阈值。