不锈钢板的CO2激光切割工艺研究

实验用CO2激光切割厚0.8mm的1Cr18Ni9Ti不锈钢板。研究了激光功率、辅助气体类型及压力、切割速度对切割质量的影响。实验显示提高切割速度能降低切缝宽度和切口横截面的表面粗糙度;而提高激光功率和氧气压力,切缝宽度也会随之提高,切口横截面更粗糙。功率650~700W、氧气压力0.3~0.5MPa、切割速度3.5~4.5m/min时切割质量最好。另外发现功率在780~1450W,氮气压力低于0.8MPa不能得到良好的切割质量。     

Dual gas jet-assisted fibre laser blind cutting of dry pine wood by statistical modelling

This paper presents a statistical analysis of the performance of an Ytterbium fibre laser utilising single and dual gas jets in a single pass to blind cut dry pine wood. Cutting wood with lasers is a multi-factor process and a proper combination of the parameters involved is needed to achieve high quality and optimum process efficiency. This study employs design of experiments and statistical modelling approach to investigate the significant process parameters along with their interactions. A high brightness, 1 kW IPG single mode Ytterbium-doped fibre laser was employed to produce blind cuts on samples of dry pine wood. The experiments were performed parallel to the direction of the wood fibre. The parameters investigated include laser power, focal plane position, traverse speed, gas pressure and single and dual gas jets. Results were compared using a number of process responses which define the efficiency of the cut in terms of kerf depth, mass removal and energy consumption as well as quality of the cut section considering the heat-affected zone, kerf width and roughness of the edge of the surface. It has been found that application of an additional gas jet produced a surface finish superior to the single jet.     

Parametric studies on the CO2 laser cutting of Kevlar-49 composite

In the present study, the cutting performance of a CO₂ laser on Kevlar-49 composite materials has been studied. The Taguchi technique is employed to identify the effect of laser control parameters, i.e., laser power, cutting speed, material thickness, assistance gas pressure, and laser mode, on the quality of cut parameters, namely, kerf width, dross height, and slope of the cut. From the analysis of variance (ANOVA) and signal-to-noise (S/N) ratio response tables, the significant parameters and the optimal combination levels of cutting parameters are determined. The obtained results are interpreted and modeled to closely understand the behavior and quality of CO₂ laser cutting. Kevlar-49 composites are found to be cut satisfactorily by the CO₂ laser at the optimum process parameter ranges. The results showed that laser power is the most significant parameter affecting the quality of cut parameters. The optimal combination of cutting parameters minimized the kerf width, dross height, and slope of cut to 0.103 mm, 0.101 mm, and 2.06°, respectively. The error between experimental results with optimum settings and the predicted values for the kerf width, dross height, and slope of cut lie within 2.9%, 7.92%, and 6.3%, respectively.     

CO2 laser cutting of Kevlar laminate: influence of assisting gas pressure

In the present study, laser cutting of Kevlar laminate is considered, and the effect of assisting gas pressure and laser output power on the end product quality is examined. The end product quality is judged via measurement of out-of-flatness and kerf width ratios. Experimental tests are carried out using a CO₂ laser beam with pulse repetition rate of 300 Hz. The cutting model introduced previously is accommodated to predict the kerf size for various laser output power and assisting gas pressures. The predictions are compared with the experimental results. It is found that the predictions of kerf size are in good agreement with the experimental results. The influence of assisting gas pressure is significant on the resulting cut quality, in which case, out-of-flatness and kerf width ratio improve considerably at high assisting gas pressures (500 kPa).     

The effect of laser cutting parameters on the formability of complex phase steel

An experimental advanced high-strength steel grade CP700 was cut using a matrix of laser process parameters in order to generate an understanding of the influence that traverse cutting speed, power and assist gas pressure have on cut-edge formation. The formation of laser cut-edges has been assessed and related to the heat-affected zone microstructure, kerf perpendicularity, surface roughness and waviness properties. It is these characteristics that are significant towards influencing the hole expansion capacity formability properties of laser cut-edges, which were determined to show significant improvements in the formability when using optimum laser cut-edges. Understanding the effect of laser cutting process parameters on the factors influencing striation formation and microstructural deformations was critical towards being able to produce an optimum level of formability.     

Development of an algorithm for optimum control process to compensate the nozzle wear effect in cutting the hard and tough material using abrasive water jet cutting process

In the process of abrasive water jet cutting, the change of nozzle diameter, due to nozzle wearing throughout cutting process, causes a decrease in surface quality and an increase in kerf width. In this paper, a series of experiments have been done to determine the effect of process parameters and the results show that traverse speed and nozzle diameter are significant parameters on the kerf quality and geometry, and a control program algorithm is suggested to compensate the effect of nozzle diameter increase on cut surface quality and kerf width and the control program creates an offset with required amount in nozzle path.     

Finite element analysis of laser inert gas cutting on Inconel 718

Inconel 718 has high strength, which makes it difficult to cut using conventional cutting methods. In the present study, the laser inert gas cutting of Inconel 718 was simulated by finite element analysis software ANSYS. Finite element method was used to predict thermal stress and kerf width formation during the laser cutting process. ANSYS Parameter Design Language was used to model the Gaussian-distributed heat flux from the laser beam acting on the workpiece. The removal of melted material during laser cutting to form the kerf width was modeled by employing the element death methodology in ANSYS. In addition, laser cutting was simulated at continuous wave (CW) and the effects of laser power and cutting speed on kerf width were investigated. A series of experiments were carried out to verify the predictions. The temperature fields on the workpiece were measured using thermocouples. The kerf width size was measured using a profile projector, whereas the metallurgical and morphological changes at the cutting edge were examined using scanning electron microscopy. A good correlation was found between the simulation and experimental results.     

Evaluation of cutting quality of PMMA using CO2 lasers

Polymethyl methacrylate (PMMA) is a versatile thermoplastic that is well suited for engineering and many common applications. This article presents a study to evaluate the effect of the processing parameters (laser power and cutting velocity) under the quality of the cut of PMMA. A plan of experiments was established considering CO₂ laser cutting with prefixed processing parameters in plates of PMMA with 6 mm thickness. The objective was to evaluate the quality of the cut (surface roughness, dimensional precision and heat affected zone-HAZ) in linear and complex 2D cutting. The obtained results show that PMMA in complex 2D cutting presents dimension of HAZ between 0.12 to 0.37 mm, without burr and low surface roughness Ra?<?1 μm. The results present good repeatability.     

Laser hole cutting in Kevlar: modeling and quality assessment

Machining of Kevlar laminates with conventional methods results in poor end-product quality and excessive specific energy requirement for machining. However, laser machining has considerable advantages over the conventional methods due to precision and rapid processing. In the present study, laser hole cutting into Kevlar laminates with different thicknesses and properties is carried out. The laser output power, frequency, and cutting speed are varied during the hole-cutting experiments. The specific energy requirements for cutting, thermal efficiency of the cutting process, and kerf width are formulated and predicted for various laser parameters and Kevlar properties. The cut quality is associated with the damage size around the holes cut and statistical analysis is carried out to examine the affecting parameters on the damaged size. It is found that specific energy requirement is significantly lower than that of the conventional drilling method. The damage size is affected significantly by the laser irradiated power. The quality of holes, as judged by the percentage of damage size around the cut edges cut by a laser beam, is considerably improved compared to the conventional methods.     

Using a Nd:YAG laser and six axes robot to cut zinc-coated steel

Zinc-coated steel sheets are important materials in the automobile and home appliance industries. Currently, lasers are the preferred tools for metal cutting because of their good cutting quality, flexibility and excellent features and results, as compared to traditional tools. The solid-state Nd:YAG laser has successfully replaced the gaseous CO₂ laser for metal cutting; its small size and short wavelength makes it suitable for cutting bright and metal-coated materials, as well as being able to be transmitted via optical fibers and robots to cut complicated three dimensional and curved shapes. In this work, the Nd:YAG laser is used to cut 1 mm zinc coated steel sheets. We demonstrate the effects of different cutting parameters such as laser power, cutting speed, different gas types and pressures, and focus position on the cutting quality characteristics of attached dross, kerf width and cut surface roughness. Using a six axes robot, cutting speed was limited to 6 m/min because of the noticeable vibration at higher speeds. Results showed that the cutting surfaces achieved were very sharp and smooth. In cutting, Nd:YAG required less power and attained higher speeds than the published results of a CO₂ laser, which makes Nd:YAG an economical alternative to cut zinc and metal-coated materials. In addition, laser cutting using robots provided efficient and consistent cutting quality, especially in the case of 3D and countered cutting. Apart from using low speed, robots proved to be more economical than costly, specially designed CNC tables.     

A study on the use of single mesh size abrasives in abrasive waterjet machining

This paper details the studies on the use of single mesh size garnet abrasives in abrasive waterjet machining for cutting aluminum. The influence of three different single mesh size abrasives, pressure, traverse rate, and abrasive flow rate; on depth of cut, top kerf width, bottom kerf width, kerf taper, and surface roughness are investigated. Experiments designed using standard L9 orthogonal array and the analysis of variance helped in the determination of highly significant, significant and weakly significant cutting parameters. Single mesh size abrasives are found to yield decreased surface roughness than multi mesh size abrasives. Based on these studies, response equations are developed to predict the target parameters. Using single mesh abrasives, a practitioner not only can cut faster but also achieve reduced surface roughness.     

Improved solutions for job shop scheduling problems through genetic algorithm with a different method of schedule deduction

This paper details the studies on the use of single mesh size garnet abrasives in abrasive waterjet machining for cutting aluminum. The influence of three different single mesh size abrasives, pressure, traverse rate, and abrasive flow rate; on depth of cut, top kerf width, bottom kerf width, kerf taper, and surface roughness are investigated. Experiments designed using standard L9 orthogonal array and the analysis of variance helped in the determination of highly significant, significant and weakly significant cutting parameters. Single mesh size abrasives are found to yield decreased surface roughness than multi mesh size abrasives. Based on these studies, response equations are developed to predict the target parameters. Using single mesh abrasives, a practitioner not only can cut faster but also achieve reduced surface roughness.     

大功率激光切割机切割工艺参数分析

初步探讨了影响激光切割碳素结构钢板切割质量的因素,在其他参数不变的情况下,最小打孔功率和最小无"挂渣"切割功率随着板材厚度的增加而增大;切缝断面粗糙度随着切割气体压力和切割速度先减小后增大。     

Some studies into wire electro-discharge machining of alumina particulate-reinforced aluminum matrix composites

Non-traditional process like wire electro-discharge machining is found to show a promise for machining metal matrix composites. However, the machining information for the difficult-to-machine particle-reinforced material is inadequate. This paper is focused on experimental investigation to examine the effect of electrical as well as non-electrical machining parameters on performance in wire electro-discharge machining of metal matrix composites (Al/Al₂O₃p). Taguchi orthogonal array was used to study the effect of combination of reinforcement, current, pulse on-time, off-time, servo reference voltage, maximum feed speed, wire speed, flushing pressure and wire tension on cutting speed, surface finish, and kerf width. Reinforcement percentage, current, and on-time was found to have significant effect on cutting rate, surface finish, and kerf width. The optimum machining parameter combinations were obtained for surface finish, cutting speed, and kerf width separately. Wire breakages were found to pose limitations on the cutting speed in machining of these materials. Wire shifting was found to deteriorate the machined surfaces.     

Empirical models and optimal cutting parameters for cutting forces and surface roughness in hard milling of AISI H13 steel

In the present research, an attempt has been made to experimentally investigate the effects of cutting parameters on cutting forces and surface roughness in hard milling of AISI H13 steel with coated carbide tools. Based on Taguchi’s method, four-factor (cutting speed, feed, radial depth of cut, and axial depth of cut) four-level orthogonal experiments were employed. Three cutting force components and roughness of machined surface were measured, and then range analysis and analysis of variance (ANOVA) are performed. It is found that the axial depth of cut and the feed are the two dominant factors affecting the cutting forces. The optimal cutting parameters for minimal cutting forces and surface roughness in the range of this experiment under these experimental conditions are searched. Two empirical models for cutting forces and surface roughness are established, and ANOVA indicates that a linear model best fits the variation of cutting forces while a quadratic model best describes the variation of surface roughness. Surface roughness under some cutting parameters is less than 0.25 μm, which shows that finish hard milling is an alternative to grinding process in die and mold industry.     

Investigation on the effect of cutting fluid pressure on surface quality measurement in high speed thread milling of brass alloy (C3600) and aluminium alloy (5083)

The quality of a machined finish plays a major role in the performance of milling operations, good surface quality can significantly improve fatigue strength, corrosion resistance, or creep behaviour as well as surface friction. In this study, the effect of cutting parameters and cutting fluid pressure on the quality measurement of the surface of the crest for threads milled during high speed milling operations has been scrutinised. Cutting fluid pressure, feed rate and spindle speed were the input parameters whilst minimising surface roughness on the crest of the thread was the target. The experimental study was designed using the Taguchi L32 array. Analysing and modelling the effective parameters were carried out using both a multi-layer perceptron (MLP) and radial basis function (RBF) artificial neural networks (ANNs). These were shown to be highly adept for such tasks. In this paper, the analysis of surface roughness at the crest of the thread in high speed thread milling using a high accuracy optical profile-meter is an original contribution to the literature. The experimental results demonstrated that the surface quality in the crest of the thread was improved by increasing cutting speed, feed rate ranging 0.41–0.45 m/min and cutting fluid pressure ranging 2–3.5 bars. These outcomes characterised the ANN as a promising application for surface profile modelling in precision machining.     

Prediction of cutting force, tool wear and surface roughness of Al6061/SiC composite for end milling operations using RSM

The results of mathematical modeling and the experimental investigation on the machinability of aluminium (Al6061) silicon carbide particulate (SiCp) metal matrix composite (MMC) during end milling process is analyzed. The machining was difficult to cut the material because of its hardness and wear resistance due to its abrasive nature of reinforcement element. The influence of machining parameters such as spindle speed, feed rate, depth of cut and nose radius on the cutting force has been investigated. The influence of the length of machining on the tool wear and the machining parameters on the surface finish criteria have been determined through the response surface methodology (RSM) prediction model. The prediction model is also used to determine the combined effect of machining parameters on the cutting force, tool wear and surface roughness. The results of the model were compared with the experimental results and found to be good agreement with them. The results of prediction model help in the selection of process parameters to reduce the cutting force, tool wear and surface roughness, which ensures quality of milling processes.     

Dimensional analyses and surface quality of the laser cutting process for engineering plastics

In this study, the effect of the CO₂ laser cutting process parameters (gas pressure, cutting speed, and laser power) on the dimensional accuracy and measured surface roughness of engineering plastic (PTFE and POM) materials was investigated. Cutting surface profile of specimens was examined by using an optical microscope. The surface quality of specimens was examined by measuring surface roughness and form error. Analysis of variance (ANOVA) and regression analyses are employed to assess the effect of the process parameters on the dimensional accuracy.     

Multiple quality optimization in laser cutting of difficult-to-laser-cut material using grey–fuzzy methodology

This paper investigates the laser cutting performance of 1 mm Duralumin sheet with the aim to improve quality of cut by simultaneously optimising multiple performances such as cut edge surface roughness, kerf taper and kerf width. The experimental data obtained by Taguchi methodology-based L₂₇ orthogonal array experimentation have been used in the hybrid approach optimization of grey relational analysis and fuzzy logic theory. The predicted optimum results have been verified by conducting confirmation experiments. The verification results show an overall improvement of 19 % in multiple quality characteristics. The effects of significant factors on quality characteristics have also been discussed.     

超声波振动精密切削GFRP的实验研究

为改善玻璃纤维增强塑料(Glass Fibre Reinforced Plastics)的切削加工性,提高加工精度和质量,采用超声波振动切削的方式对GFRP进行了精密切削加工.介绍了超声波振动切削的特性和GFRP的纤维束与切削速度方向的相位参数,相位参数沿圆周方向成周期性变化,变化周期为π.通过实验获得了不同切削条件下表面粗糙度的变化规律,粗糙度随相位角变化基本呈正弦规律,但在45°时粗糙度最大.振幅增大导致粗糙度明显下降.切削速度对粗糙度的变化曲线呈极值状态,在速度为100 m/min时粗糙度最小.进给量小于0.06 mm时,粗糙度呈下降趋势;大于0.06 mm时,粗糙度增加较快;而大于0.09 mm后粗糙度上升趋缓.切削深度对粗糙度的影响呈单调上升趋势.实验结果表明超声波振动切削可以使GFRP的加工表面粗糙度减少1倍,使加工质量得以提高.