An applicable review on recent laser beam cutting process characteristics modeling: geometrical, metallurgical, mechanical, and defect

Nabavi, Seyedeh Fatemeh; Farshidianfar, Anooshiravan; Dalir, Hamid

doi:10.1007/s00170-023-12812-0

Cited by 6 publications

(4 citation statements)

References 173 publications

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“…A conformal cooling channel (CCC) [ 1 ] refers to a specific category of the cooling system designed for dies or molds used in various manufacturing processes, such as blow molding [ 2 ], metal forming [ 3 ], plastic injection molding [ 4 ], die casting [ 5 ], and metal injection molding [ 6 ]. The feature of CCC is to optimize heat dissipation during the cooling stage of the various manufacturing processes.…”

Section: Introductionmentioning

confidence: 99%

Development of a Silicone Rubber Mold with an Innovative Waterfall Cooling Channel

Kuo,

Lin,

et al. 2024

Polymers

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A conformal cooling channel (CCC) follows the mold core or cavity profile to carry out uniform cooling in the cooling stage. However, the significant pressure drop along the cooling channels is a distinct disadvantage of the CCC. In this study, an innovative waterfall cooling channel (WCC) was proposed and implemented. The WCC cools the injected products via surface contact, replacing the conventional line contact to cool the injected products. The WCC was optimized using numerical simulation software. Silicone rubber molds with two kinds of cooling channels were designed and implemented. The cooling time of the molded part was evaluated using a low-pressure wax injection molding machine. The experimental results of the cooling time of the molded part were compared with the simulation results from numerical simulation software. The results showed that the optimal mesh element count was about 1,550,000 with a mesh size of 1 mm. The simulation software predicted the filling time of the water cup injection-molded product to be approximately 2.008 s. The cooling efficiency for a silicone rubber mold with a WCC is better than that of the silicone rubber mold with a CCC since the core and cavity cooling efficiency is close to 50%. The pressure drop of the WCC is smaller than that of the CCC, which reduces the pressure drop by about 56%. Taking a water cup with a mouth diameter of 70 mm, a height of 60 mm, and a thickness of 2 mm as an example, the experimental results confirmed that the use of the WCC can save the cooling time of the product by about 265 s compared with the CCC. This shows how a WCC can increase cooling efficiency by approximately 17.47%.

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Section: Introductionmentioning

confidence: 99%

Development of a Silicone Rubber Mold with an Innovative Waterfall Cooling Channel

Kuo,

Lin,

et al. 2024

Polymers

View full text Add to dashboard Cite

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“…In recent years, the adoption of conformal cooling channels (CCs) [1] in injection molds or dies has emerged as a widely recommended standard for enhancing mold capabilities. CC denotes a specialized type of cooling system tailored for dies or molds employed in diverse manufacturing processes, including blow molding [2], metal forming [3], plastic injection molding [4], die casting [5], and metal injection molding. The distinctive characteristic of CC lies in its capacity to enhance heat dissipation during the cooling phase across various manufacturing operations.…”

Section: Introductionmentioning

confidence: 99%

Enhancing the Cooling Efficiency of Aluminum-Filled Epoxy Resin Rapid Tool by Changing Inner Surface Roughness of Cooling Channels

Kuo,

Chen,

Lin

et al. 2024

Polymers

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In low-pressure wax injection molding, cooling time refers to the period during which the molten plastic inside the mold solidifies and cools down to a temperature where it can be safely ejected without deformation. However, cooling efficiency for the mass production of injection-molded wax patterns is crucial. This work aims to investigate the impact of varying surface roughness on the inner walls of the cooling channel on the cooling efficiency of an aluminum-filled epoxy resin rapid tool. It was found that the cooling time for the injection-molded products can be determined by the surface roughness according to the proposed prediction equation. Employing fiber laser processing on high-speed steel rods allows for the creation of microstructures with different surface roughness levels. Results demonstrate a clear link between the surface roughness of cooling channel walls and cooling time for molded wax patterns. Employing an aluminum-filled epoxy resin rapid tool with a surface roughness of 4.9 µm for low-pressure wax injection molding can save time, with a cooling efficiency improvement of approximately 34%. Utilizing an aluminum-filled epoxy resin rapid tool with a surface roughness of 4.9 µm on the inner walls of the cooling channel can save the cooling time by up to approximately 60%. These findings underscore the significant role of cooling channel surface roughness in optimizing injection molding processes for enhanced efficiency.

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“…Laser cutting is an advanced manufacturing process that has found many applications in fabricating various types of products [1]. From drilling holes to milling sheet plates, laser cutting is recommended for superior surface integrity results.…”

Section: Introductionmentioning

confidence: 99%

“…The most economic trial planner that accommodates non-linear relationships into a compact design and serves as many as four controlling factors is the L 9 (3 4 ) OA. The replicated trial plan will be treated with two different approaches: (1) to profile the strong effects for each process/product characteristic, and (2) to obtain an optimal multifactorial solution by synchronously minimizing all four examined characteristics. To accomplish the former task, the Gibbs sampling method is used to form the multi-distribution marginal densities [42][43][44][45].…”

Section: Introductionmentioning

confidence: 99%

Lean-and-Green Datacentric Engineering in Laser Cutting: Non-Linear Orthogonal Multivariate Screening Using Gibbs Sampling and Pareto Frontier

Sembou,

Besseris

2024

Processes

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Metal processing may benefit from innovative lean-and-green datacentric engineering techniques. Broad process improvement opportunities in the efficient usage of materials and energy are anticipated (United Nations Sustainable Development Goals #9, 12). A CO2 laser cutting method is investigated in this study in terms of product characteristics (surface roughness (SR)) and process characteristics (energy (EC) and gas consumption (GC) as well as cutting time (CT)). The examined laser cutter controlling factors were as follows: (1) the laser power (LP), (2) the cutting speed (CS), (3) the gas pressure (GP) and, (4) the laser focus length (F). The selected 10mm-thick carbon steel (EN10025 St37-2) workpiece was arranged to have various geometric configurations so as to simulate a variety of real industrial milling demands. Non-linear saturated screening/optimization trials were planned using the Taguchi-type L9(34) orthogonal array. The resulting multivariate dataset was treated using a combination of the Gibbs sampler and the Pareto frontier method in order to approximate the strength of the studied effects and to find a solution that comprises the minimization of all the tested process/product characteristics. The Pareto frontier optimal solution was (EC, GC, CT, SR) = (4.67 kWh, 20.35 Nm3, 21 s, 5.992 μm) for the synchronous screening/optimization of the four characteristics. The respective factorial settings were optimally adjusted at the four inputs (LP, CS, GP, F) located at (4 kW, 1.9 mm/min, 0.75 bar, +2.25 mm). The linear regression analysis was aided by the Gibbs sampler and promoted the laser power and the cutting speed on energy consumption to be stronger effects. Similarly, a strong effect was identified of the cutting speed and the gas pressure on gas consumption as well as a reciprocal effect of the cutting speed on the cutting time. Further industrial explorations may involve more intricate workpiece geometries, burr formation phenomena, and process economics.

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An applicable review on recent laser beam cutting process characteristics modeling: geometrical, metallurgical, mechanical, and defect

Cited by 6 publications

References 173 publications

Development of a Silicone Rubber Mold with an Innovative Waterfall Cooling Channel

Development of a Silicone Rubber Mold with an Innovative Waterfall Cooling Channel

Enhancing the Cooling Efficiency of Aluminum-Filled Epoxy Resin Rapid Tool by Changing Inner Surface Roughness of Cooling Channels

Lean-and-Green Datacentric Engineering in Laser Cutting: Non-Linear Orthogonal Multivariate Screening Using Gibbs Sampling and Pareto Frontier

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