Annular laser beams provide a drilling mechanism that can be referred to as optical trepanning. In this paper an analytical two-dimensional model is developed for optical trepanning. The analysis accounts for conduction in the solid, vaporization, and convection due to the melt flow caused by an assist gas. Based on the model, the influences of pulse duration, laser-pulse length, pulse repetition rate, intensity profiles, and beam radius are investigated to examine their effects on the recast layer thickness, hole depth, and taper. Deeper cavity depth, thicker recast layer, and larger taper are obtained with the increase in the laser intensity. By using different types of intensity profiles, the nature of the hole taper can be modified, i.e., convergent or divergent holes can be produced. The effects of the inner radius of annular beams are more significant than other laser parameters. An increase in the inner radius reduces the hole taper and produces thinner recast layer and deeper cavity depth.
Optical trepanning is a new laser drilling method using an annular beam. Since laser heating of the substrate occurs first due to heat conduction, this article investigates the temperature distribution in the workpiece due to pulsed annular laser beams by solving an axisymmetric transient heat conduction equation. The annular beams allow numerous irradiance profiles to supply laser energy to the workpiece and thus provide more flexibility in affecting the hole quality than a traditional circular laser beam. Such profiles include half Gaussian with maximum intensities at the inner and outer radii of the annulus, respectively, and full Gaussian with maximum intensity within the annulus. In addition to this spatial beam shaping, the temporal profile of the laser pulse can be shaped to improve the hole quality. The Hankel and Laplace transforms have been used to obtain an analytic solution for the temperature distribution in a semi-infinite workpiece. The effects of the temperature distribution on laser drilling are analyzed to understand the influence of different laser parameters on the drilling process.
An annular beam provides a new laser drilling mechanism, which we refer to as optical trepanning. A refractive axicon system has been designed to transform an input Gaussian laser beam into a collimated annular beam. The diffractive effects of the axicon system and a convex lens focusing the collimated annular beam have been studied using the Fresnel diffraction integral. The theoretical diffraction patterns are compared with the patterns measured with a laser-beam analyzer. The results show that the refractive axicon system can produce Gaussian-like annular beams with the capability of easily adjusting the size of the annular beam.
Laser drilling is very important in many industries such as automotive, aerospace, electronics, and materials processing. It can be used to produce critical components with novel hole geometry for advanced systems. Percussion drilling and trepanning are two laser drilling methods. In the conventional trepanning method, a laser beam is scanned along a circular or spiral orbit to remove material to achieve a desired hole shape. These orbits generally trace a circular path at the inner wall of the holes. This suggests that an annular beam can be used to accomplish trepanning, a technique we refer to as optical trepanning. The ray-tracing technique of geometrical optics is employed in this paper to design the necessary optics to transform a Gaussian laser beam into an annular beam of different intensity profiles. Such profiles include uniform intensity within the annulus, full Gaussian with maximum intensity, and half Gaussian with maximum intensities at the inner and outer surfaces of the annulus.
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