Comparative analysis of tangentially laser-processed fluted polycrystalline diamond drilling tools

Warhanek, Maximilian; Walter, Christian; Hirschi, M.; Boos, Jens; Bucourt, J.F.; Wegener, Konrad

doi:10.1016/j.jmapro.2016.06.023

“…Recently, ultra-short pulsed laser systems are becoming more affordable and increasingly applied by industry [11]. An example is the production of cutting tools, like end mills and drills with diamond cutting edges [12,13]. The kinematics of quasi-tangential laser processing is similar to the wire electric-discharge machining (EDM) process and the developed CAM models [14] can be facilitated partially.…”

Section: Introductionmentioning

confidence: 99%

Path calculation of 7-axes synchronous quasi-tangential laser manufacturing

Ackerl

¹

,

Warhanek

²

,

Gysel

³

et al. 2019

Int J Adv Manuf Technol

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Quasi-tangential laser processing, also called laser turning is increasingly applied for various applications. Specifically, its ability to generate complex geometries with small feature sizes at high precision and surface quality in hard, brittle and electrically non-conductive materials. Due to the geometric flexibility, the process is well suited for prototyping in hard-to-machine materials such as ceramics, carbides and super-abrasives. However, the lack of advanced software solutions for this novel process hitherto limited the exploitation of this potential. Here, we discuss a unique computer-aided manufacturing approach for synchronous 7axis laser manufacturing with quasi-tangential strategies. This gives the peerless possibility to process arbitrary geometries, which cannot be manufactured with conventional techniques. A detailed description of the path calculation with derivation and procedures is given. The generated machine code is tested on a 7-axis laser manufacturing setup. Following, a processed cylindrical ceramic specimen with a continuously varying profile along a helical path is presented. The profile is constituted by a rectangular over half-spherical to a triangular groove with defined pitch. This demonstrator provides the validation of this CAM solution. Measurements of the produced specimen show high adherence with the target geometry with an average deviation below 10 µm.

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“…Therefore, sintered ceramics are highly difficult to machine properly with conventional processes. The standard process chain for dental implants is 20 to produce a diamond grinding wheel for the adjacent target geometry and grind the sintered workpiece. Hence, a change in the geometry requires a new grinding tool.…”

Section: Introductionmentioning

confidence: 99%

“…Hence, case of cylindrical workpieces the process is translated to quasi-tangential ablation conditions, shown in figure 1b. This has been successfully used for the manufacturing of ultrahard cutting tools with high precision [20].…”

Section: Introductionmentioning

confidence: 99%

Ultrashort-Pulsed Laser Machining of Dental Ceramic Implants

Ackerl¹,

Warhanek²,

Gysel³

et al. 2018

Preprint

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A novel approach for machining of cylindrical hard materials and arbitrary shapes is presented. Alumina-toughened zirconia dental implants with complex geometry are manufactured with femtosecond quasi-tangential laser ablation. This rapid-prototyping approach for small-scale production decreases the development-time cycle tremendously and trumps conventional approaches. Moreover, a competitive parameter study for radial and tangential ablation with single and multi-pulse is presented. A process achieving an ablation rate of 1mm3/min with a surface roughness Ra of 0.2 µm is introduced. The meta-stable tetragonal phase of the ceramic persists and is assessed via Raman spectroscopy. The small heat-affected zone is subsequently ablated with a radial laser process step. Hence, high-precision dental implants with a mean error of smaller 5 µm over the complete contour are shown.

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“…Recently, ultra-short pulsed laser systems are becoming more affordable and increasingly applied by industry [11]. An example is the production of cutting tools, like end mills and drills with diamond cutting edges [12,13]. The kinematics of quasi-tangential laser processing is similar to the wire electric-discharge machining (EDM) process and the developed CAM models [14] can be facilitated partially.…”

Section: Introductionmentioning

confidence: 99%

“…The incidence is tangential to the target, but the beam moved about one focal radius inside the material and therefore termed quasi-tangential. Hence, the relative movement of work piece and laser is assembled by a superposition of a spiral 40 motion of the workpiece and the laser scanning with highly dynamic motion by a galvo scanner [13]. Subsequently, the laser hatches are computed for each point on the helical path.…”

Section: Introductionmentioning

confidence: 99%

Path Calculation of 7-axes Synchronous Quasi-Tangential Laser Manufacturing

Ackerl¹,

Warhanek²,

Gysel³

et al. 2018

Preprint

View full text Add to dashboard Cite

Quasi-tangential laser processing, also called laser turning is increasingly applied for various applications. Specifically, its ability to generate complex geometries with small feature sizes at high precision and surface quality in hard, brittle and electrically non-conductive materials. Due to the geometric flexibility, the process is well suited for prototyping in hard-to-machine materials such as ceramics, carbides and super-abrasives. However, the lack of advanced software solutions for this novel process hitherto limited the exploitation of this potential. Here, we discuss a unique computer-aided manufacturing approach for synchronous 7axis laser manufacturing with quasi-tangential strategies. This gives the peerless possibility to process arbitrary geometries, which cannot be manufactured with conventional techniques. A detailed description of the path calculation with derivation and procedures is given. The generated machine code is tested on a 7-axis laser manufacturing setup. Following, a processed cylindrical ceramic specimen with a continuously varying profile along a helical path is presented. The profile is constituted by a rectangular over half-spherical to a triangular groove with defined pitch. This demonstrator provides the validation of this CAM solution. Measurements of the produced specimen show high adherence with the target geometry with an average deviation below 10 µm.profile on a helical pitch within the physical limitations of laser processing can be produced. After a detailed discussion of the necessary functionality of the CAM solution the experimental result is presented as validation of this unique concept. CAM Modules 70There are general approaches on CAM programming for various manufacturing techniques like milling [20], drilling and grinding [21]. However, laser manufacturing has to be treated differently, taking into account the non-binary behavior with the workpiece [22]. The interaction of the laser beam with the material depends on several parameters with non-linear behavior. The most 75 influencing dependencies concern the laser wavelength λ, polarization P , pulse duration τ P , fluence F , angle of incidence θ i , the materials susceptibility χ and

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Comparative analysis of tangentially laser-processed fluted polycrystalline diamond drilling tools

Cited by 22 publications

References 18 publications

Path calculation of 7-axes synchronous quasi-tangential laser manufacturing

Path calculation of 7-axes synchronous quasi-tangential laser manufacturing

Ultrashort-Pulsed Laser Machining of Dental Ceramic Implants

Path Calculation of 7-axes Synchronous Quasi-Tangential Laser Manufacturing

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